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Atlas Copco Enhanced miniMACS Manual

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1. User Manual Enhanced miniMACS User Manual Enhanced miniMACS User Manual Enhanced miniMACS ded gt lt MinAngleNotReached gt Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com lt MaxAngleExceeded gt lt MinTorqueNotReached gt lt MaxTorqueExceeded gt lt MStopActivated gt lt SpindleError gt lt CalibrationError gt lt OffsetError gt lt OverFlowError gt lt DCBusLow gt lt FinalTorqueOK gt lt FinalAngleOk gt lt TimeOutExceeded gt 1 0 1 indicates that the event occurred lt MinAngleNotReached gt 1 0 1 indicates that the event occurred lt MaxAngleExceeded gt 1 0 1 indicates that the event occurred lt MinTorqueNotReached gt 1 0 1 indicates that the event occurred lt MaxTorqueExceeded gt 1 0 1 indicates that the event occurred lt MStopActivated gt 1 0 1 indicates that the event occurred lt SpindleError gt r 1 0 1 indicates that the event occurred lt CalibrationError gt 1 0 1 indicates that the event occurred lt OffsetError gt 1 0 1 indicates that the event occurred lt OverFlowError gt 1 0 1 indicates that the event occurred lt DCBus Low gt 1 0 1 indicates that the event occurred lt FinalTorqueOK gt r 1 0 1 indicates that the event occurred lt FinalAngleOk gt 1 0 1 indicates that the event occurred lt alphaNumStr gt
2. A sequence of alpha numerical characters including space lt numStr gt A sequence of numerical characters lt floatStr gt A sequence of numerical characters and an optional dot as decimal point that Can be interpreted as a float value lt dateStr gt A sequence of characters that makes up a date formatted as yyyy mm dd lt timeStr gt A sequence of characters that makes up a time formatted as hh mm ss HT lt Horizontal tab gt decimal ASCIll code 9 EOL lt Carriage return gt lt Line feed gt decimal ASCll codes 13 and 10 Example of the message body HEAD 99 Flywheel 11ABC 990260001 1999 01 28 15750351 ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 46 User Manual Enhanced miniMACS Introduction 46 User Manual Enhanced miniMACS Start up Instructions 46 User Manual Enhanced miniMACS Glossary of Terms 46 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com NOK 2 SPINDLES 1 2 2 1 0 3 20 120 0 60 0 360 0 0 000000000011 2 2 3 1 0 3 0 420 0 60 0 360 0 0 001000000010 End of cycle data This telegram is sent to the MMS server from WinQCM to indicate that there are no cycle data to transfer The telegram has the following format it has no message body lt telegram type gt 4 decimal ASCIll code 52 lt message body gt not valid Example STX 4 ETX or as decimal ASCII codes 02 52 03
3. 2000 04 27 10 17 22 SeqNo 14117 Set 1 EUN 01234 4990015678 Sp 1 Step 2 NOK Torque high Sp 2 Step 4 OK The Reject Report window displays a list of all NOK cycles For each NOK cycle the following are listed e Date and time for the start of the cycle e The EUN code e The set of the cycle e A sequence number that is the same as the sequence number in MMS And for each spindle in the station e The spindle number The step number of the reported step Whether or not it is inhibited Status OK NOK The reject cause if status is NOK Above the list the percentage of NOK cycles number of NOK cycles 1000 100 ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 36 User Manual Enhanced miniMACS Introduction 36 User Manual Enhanced miniMACS Start up Instructions 36 User Manual Enhanced miniMACS Glossary of Terms 36 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com are shown Press the button Refresh to refresh the current list and press the button Print to have the current view on paper To print only a part of the list make a selection in the list press Print and choose Print Selection End of shift report You can set up that an End of Shift Report should be printed automatically at the end of each shift The report consists of the following data The number of cycles executed since buffers where cleared see below when buffers are clear
4. Configuration of the Station Controller The Station Controller application program must be adopted to the current installation of the miniMACS system before it will work properly To do this you need to have access to an OpenControl development environment You get access to the development environment by using a special dongle Before the configuration can start you must start OpenControl and select the Station Controller as the current project Do the following e Start OpenControl e Select the menu item File Open Project This will display a dialogue in which you select the latest version of the Station Controller application e g SC_v_1_4 using the drop down combo box ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 78 User Manual Enhanced miniMACS Introduction 78 User Manual Enhanced miniMACS Start up Instructions 78 User Manual Enhanced miniMACS Glossary of Terms 78 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Setting the Profibus slave address Which slave address the Station Controller should have on the Automation PC s Profibus net varies from site to site To change it do the following Flow Chart InterBus Configurator ogic Memory SDS Configurator i Seriplex Configurator Lobel seamen UBT IAPC_EUN_Comp_Idt AUB2 IAPC_EUN Comp_Id2 IUB3 IAPC_EUN_Eng_ Idi ZIUB4 IAPC EUN Eng_ld2 IUBS
5. 888 88 SOURCE www artisantg com Interface to the Automation PC The complete layout of the interface to the overriding Automation PC is presented in Appendix 2 Interface to the Automation PC Here the most important features of this interface are described Inputs The Station Controller implemented in OpenControl is controlled by the Automation PC using the following inputs items printed in italic on grey background are optional and may be used if so wanted Signal Description S The EUN code The value of this signal 16 byte sampled when a start is detected is used to mark the trace and cycle data generated during the execution of the complete tightening cycle The parameter set to This signal consists of four bits and specifies the number of the executed set that should be used as the normal tightening program Zero 0 correspond to the first set of the tightening program This input is sampled when a start order is detected Inhibit of individual spindles This signal consists of four bytes and is used to inhibit individual spindles This input is sampled when a start order is detected Start A positive edge on this signal starts the execution of a tightening cycle After being started the Station Controller ignores new start orders until it is ready for a new start This is indicated by the output signal Ready for Start Stop A high level on this signal stops the execution of a tightening cycle if executing
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7. Unknown telegram received This telegram is sent to the MMS server from WinQCM to indicate that it has received an unknown telegram The telegram has the following format lt telegram type gt 0 decimal ASCll code 48 lt message body gt MMS_SERVER Unknown message lt receivedTgmType gt lt receivedMsgBody gt Example STX 0 MMS SERVER Unknown message lt 8 gt lt xxxx gt ETX ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 47 User Manual Enhanced miniMACS Introduction 47 User Manual Enhanced miniMACS Start up Instructions 47 User Manual Enhanced miniMACS Glossary of Terms 47 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The Station Controller General The Station Controller is responsible for the co ordination of the individual servos It takes its input from the overriding Automation PC and controls the individual servos via a FBU Field Bus Unit The Station Controller is implemented as an OpenControl application and interfaces both the Automation PC and the FBU using Profibus For information on OpenControl see Ref 08 The following sections describes the function of the Station Controller It does not describe how it is designed or how it can be modified e g in order to handle group based reject management The interface to the Automation PC is described in Appendix 2 Interface to the Automation PC F
8. IAPC_EUN_Eng_ld3 ZIUBE IAPC_EUN_Space SAO KIAN FUM a te de OpenControl 4 3 Ready In the left panel select the item Profibus Configurator Profibus2 In the right panel set the correct slave address in the field Local Address Be sure to press the button OK Select the menu item File Save ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 79 User Manual Enhanced miniMACS Introduction 79 User Manual Enhanced miniMACS Start up Instructions 79 User Manual Enhanced miniMACS Glossary of Terms 79 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Setting the OpenControl parameters To use the Station Controller together with a particular tightening set up defined using WinQCM E a number of parameter must be configured see e g 4 3 Basic functionality and 4 4 Reject management To do that do the following lt OpenControl SC_ _2_3 Memory ZMUB 8 Bit Unsigned File Edit Project Tools Window Help 12 x alelu e x a S vel alels Flow Chart Insert Delete Copy Size 587 4 1001 16384 DRY Logic Memory Constants Alias wire Label Initial Value Retain Inputs 4MUB1 AREE MUB1 1 No Memory RM_Type 4MUB2 0 No 7 ZMB 8 Bit Signed MUB3 0 No MD 32 Bit Signed Setl_RM_MazFailedSpindles MUB4 0 No 7 MF 32 Bit Real Setl_
9. If not the tightening cycle is immediately terminated 4 If the system is found OK the station starts the cycle If all spindles do not start or if they do not confirm the ordered set number within 1 second the tightening cycle is terminated 5 When the cycle finishes the station triggers the WinQCM E to fetch cycle data from the spindles If all spindles finish with status OK then the tightening cycle is ended and the station output OK is set 6 If the cycle finishes NOK and reject management is enabled then the spindles are first backed using the defined back off set However before starting the back off it orders the WinQCM E to freeze the values currently displayed in its Result view If the back off cycle finishes OK then all spindles that where backed are re tightened using the defined re tightening set During this phase the Station Controller orders the WinQCM E to update the status of all spindles being re tightened 7 If the re tightening cycle finishes with OK result the tightening cycle is ended and the station reports OK as the final result If not the Station Controller will execute the configured 2 failure action ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 49 User Manual Enhanced miniMACS Introduction 49 User Manual Enhanced miniMACS Start up Instructions 49 User Manual Enhanced miniMACS Glossary of Terms 49 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURC
10. 0 2 180 h Results Tightening cycles MMS NUM Mo 7 The results step torque values angle values and error messages are shown in one line for each spindle If the status is OK the status box is green and if it s NOK the status box is red and a text string explain type of fault If the spindle is running the box is white and the status is RUNNING By clicking in the Comm Off box the selected spindle will be ignored in the CAN communication This is useful e g when one of servos is defect The step torque and angle values presented originate from the step marked in the Tightening cycles table see Tightening steps Tightening cycles Window Using the tightening cycles window you can display and edit the tightening program ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 8 User Manual Enhanced miniMACS Introduction 8 User Manual Enhanced miniMACS Start up Instructions 8 User Manual Enhanced miniMACS Glossary of Terms 8 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Satl_3sp qel WinQCM E OL x File View Spindle Setup Load parameters Accesslevel SPC Trace Report MMS Help OC GS fspinser OFF LINE Log ESC iaip Nm Sec deg rpm Nm deg A set Delay Angle ea no Step Mode Max Target min start Max Target Rev Te mc Ratio af Angle 10 0 0 0 0 0 5 230 180 140
11. 08 for a description of the OpenControl environment The MMS interface is used by other remote applications in order to access cycle data from the miniMACS PC The MMS interface is implemented as a separate application which is interfaced to the WinQCM E using a socket The Field Bus Unit or FBU receives control data from the Station Controller over the Profibus interface The FBU processes the control data and sends it to the servo drive units over the Lan1 bus The status of the drive units is sent back the same way to the Station Controller This communication chain is essential for the operation of the tightening system The QMC2 servo units performs the actual tightening During the execution of a tightening cycle they records tightening information i e torque and angle data This data is stored in internal memory and can be retrieved by the WinQCM E application over the Lan2 bus A miniMACS system may consist of up to 32 spindles ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 5 User Manual Enhanced miniMACS Introduction 5 User Manual Enhanced miniMACS Start up Instructions 5 User Manual Enhanced miniMACS Glossary of Terms 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The rest of this manual describes the parts of a miniMACS system in more detail ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 6 User Manual E
12. 2 failure action The state of the Station Controller is therefore changed to 2 failure If the re tightening cycle was found NOK and the 2 failure action is set to anything else but back off all or the currently NOK spindles then the tightening cycle is ended The station output NOK is set high Running is set low and the state of the Station Controller is changed to Waiting for start State 2 Failure The Station Controller enters this state when the if the re tightening has failed and the 2 failure action is set to either back off all spindles or to back off only the currently NOK spindles The spindles are backed using the same set as used for the back off state When state is entered the servos are prepared to run the back off set on either all spindles that where not inhibited by the Automation PC right from the start no matter their current status or only the spindles that currently are not correctly tightened The servos are therefore set up with the following the number of set to back off with the original EUN code a new cycle start time and the inhibit information according to the above ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 62 User Manual Enhanced miniMACS Introduction 62 User Manual Enhanced miniMACS Start up Instructions 62 User Manual Enhanced miniMACS Glossary of Terms 62 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE
13. 80 No Z Delay 0 0 oo 100 0 0 R 3 Angle 10 0 0 0 0 0 5 0 180 0 80 No 4 Angle End 10 0 0 0 0 0 5 0 180 0 30 No Angle 10 0 0 0 0 0 5 230 180 140 80 No 6 Delay 0 0 0 0 5 0 0 0 R32 Torque 2 0 10 00 0 0 5 o 0 100 No 8 Angle End 10 0 0 0 0 0 5 0 180 0 30 No a R39 Angle End 10 0 0 0 0 0 5 0 360 0 60 Yes a R 10 Torque End 0 0 3 0 0 0 0 0 3 0 0 100 Yes 5 R 4a Angle End 5 0 0 0 0 0 s 100 90 0 60 No fej az notused TT a a3 Not used 8 aa Not used 19 as Not used 30 a6 Not used aa a7 Not used a2 ae Not used Taa a9 Not used v NM 1545 4 A step is selected by clicking on it To change the parameters of a step double click on the step in question This will launch the Tightening steps dialogue to be opened in which you can do your modifications ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 9 User Manual Enhanced miniMACS Introduction 9 User Manual Enhanced miniMACS Start up Instructions 9 User Manual Enhanced miniMACS Glossary of Terms 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The MMS Window Using the MMS window you can study the current status of the MMS queue The MMS queue contains the result of the last cycles executed The length of the queue is default 100 cycles but is configurable See The MMS Interface for a description of the MMS queu
14. Controller Download 8 Select the FBU application software and press OK to download 9 You can monitor the download status at the bottom left of screen If the FBU does not respond by displaying its address type CTRL Z X where X represents the current FBU address E g CTRL Z 0 opens AG Type FSTORE to store new file in FBU memory Type RESET SYSTEM to reset system FBU software will now start Change the FBU Node address to 0 Default is F case sensitive Type CTRL Z F Type EEPROM 6 240 for FBU address 0 Type R50 1 Type RESET SYSTEM to reset and set node number i Unplug the PC the FBU is now set up Install NET UPS Lansafe program Put in the CD and run Lansafe NTWin Setup exe Select NetUPS After this port COM willl not be available for any other program ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 76 User Manual Enhanced miniMACS Introduction 76 User Manual Enhanced miniMACS Start up Instructions 76 User Manual Enhanced miniMACS Glossary of Terms 76 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Device drivers for the Profibus Boards When installing Open Control and with it the Profibus configurator ProfiControl device drivers are installed for the Profibus DP master board This device drive can be configured by selecting the PROFIBUS icon found in the
15. EUN 01234 4990015678 Date 1999 11 04 Time Sp 1 Set 3 T 4 1 Nm A 360 deg No errors 11 36 14 Select the spindle you are interested in by use of the Spindle fields Then use the Trace fields to select which of the traces stored for that spindle to fetch Finally press the button Add to display the trace You can also add earlier saved traces using the Select saved trace button see below Up to six traces may be displayed as the same time When a trace is added all traces already displayed will be kept as well To remove one or more traces mark them in the list of currently displayed traces in the upper right corner of the window and press the button X To remove all traces press Clear All If you press the More Data gt gt button the lower part of the window is unfolded and displays cycle data corresponding to the trace shown If more than one trace is displayed this field is cleared If several traces are displayed the x axis is scaled for the trace that is marked in the list of displayed traces The different curves are identified by different colors If you want to study a particular part of the trace you may zoom it in Place the mouse cursor on the left most position that is of interest press the left mouse button and drag the cursor to the right until the wanted area is marked and ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 33 User Manual Enhanced miniMACS Introduction 33 User Ma
16. Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix 2 Interface to the Automation PC Inputs The interface to the overriding Automation PC consists of the following input signals items printed in italic on grey background are optional and may be used if so wanted om Eo o un eg aun eg aun EE om r Bune Co Emsan heor Ce hommes hscrgureg To pommer hsorpureg Ca psa Ce puna Tia un aun Tis uno Te Tr a a o Ta 22 Spindle Bypass 25 32 inary See description below Station Byte Description Byte 18 o 1 start Starts the station i e all spindles a 2 stop Stops the station i e Machine stop to all spindles 1 2 3 4 5 7 10 11 12 13 14 15 16 17 18 19 20 21 22 a la Pendis Bit 0 ightening set binary bit O value 1 3 8 parameter Bit 1 ightening set binary bit 1 value 2 ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 88 User Manual Enhanced miniMACS Introduction 88 User Manual Enhanced miniMACS Start up Instructions 88 User Manual Enhanced miniMACS Glossary of Terms 88 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Parameter Bit 2 Tightening set binary bit 2 value 4 a2 Parameter Bit 3 Tightening set binary bit 3 value 8 64 Link alive The use of this bit is optional If the parameter SuperviseAPCLink i
17. Max speed See note 1 note 2 torque oo zooo 229 eo 27 roo of 2o00 zood 22d sze as 1 roo mof 200 eso eso 1577 1 R 2 25 80 2 46 0 30 0 47 roo sof 20001 eao eso aes 275 7 7 D D D D p oso 125 poar nd ao soo sood eoo sesa eso Note 1 The current scale factor is calculated as Ktmotor IMaxServo 100 Note 2 For spindles where the motor has opposite rotation direction from the socket holder u gear or 2 wheel offset the values shall be multiplied with 1 minus one Torque reading This function is used to configure the torque transducer It is only valid for servos of QCM S 2 T type Select a torque transducer and press the Set default values button Default parameters will then be automatically inserted ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 18 User Manual Enhanced miniMACS Introduction 18 User Manual Enhanced miniMACS Start up Instructions 18 User Manual Enhanced miniMACS Glossary of Terms 18 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com If the read values of the parameters doesn t correspond with the default values of the selected spindletype the label NOTE Not default values are displayed The Filter constant and the Input gain can be edited manually if you e g have another type of torque transducer The Torque scale factor can either be edited manually or calc
18. The communication format is CAN version 2 0 which is further detailed in Ref 06 The parameters that have to be programmed before the tightening station can be started up are the tightening step parameters defining the tightening process torque angle and speed limits etc and the spindle parameters defining the characteristics of each spindle gear ratio scaling regulator parameters etc These parameters are programmed once when the station is being commissioned and don t have to be reprogrammed until changes are to be made to the tightening cycle or a different spindle is to be used The quantitative tightening data that can be retrieved by the Station Controller are of two types reports and traces The reports of up to ten parameters can be chosen to be retrieved after each cycle while the traces containing a lot more data are retrieved only on an operators request Step Parameters The basics of the steps are described in 2 3 3 Spindle Each one of the 64 steps has 10 parameters numbered from 1 to 10 In the servo drive unit the parameters are stored internally in an EEPROM memory Depending on which control mode see 2 3 3 Spindle that is programmed into a step the included parameters are as follows Par2 Pars Pare Par7 Pars Par9 Part0 o pf amex Amin Timeout Er 2 E o j imee soes fame Amn Doiy Timeout oynatow Tie Tmax Tin Spesa ame Amn Delay Timeout Where ASYQSW99
19. Y Y Y Y Y Y es es No Yes es es No Yes es es Yes Yes es es No Yes es es No Yes es es No Yes es es Yes Yes es es No Yes es es Yes Yes ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 14 User Manual Enhanced miniMACS Introduction 14 User Manual Enhanced miniMACS Start up Instructions 14 User Manual Enhanced miniMACS Glossary of Terms 14 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Angles are programmed in degrees Max time is programmed in seconds Time for Delay and Delay End steps can be programmed with one decimal Speed is programmed in rpm In all steps except Delay and Delay End one can select to run in Reverse direction Torque is programmed in Nm or fl lb Torque values are always programmed with one decimal Max allowed torque is set up in the Spindle parameters menu When a step is Deleted the step is removed and the steps following are moved up one row As step no 64 a new empty step is added When a step is Inserted the currently selected step and the steps following will be moved down one row The step added will be an empty step When a DynaTork step is programmed a dialog appears where a Delay or Delay End step can be selected The Delay Delay End step is automatically inserted after the DynaTork step Max and Min Torque and Angle limits can be programmed to 0 meaning that the parameter is not used A clic
20. com View Spindle Setup Loadparameters Accesslevel SPC Trace Repot MMS Help Onine button v Status Bar File v Results Tightening cycles MMS Using this menu you can customise the layout of the GUI i e which windows toolbars etc that should be displayed ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 12 User Manual Enhanced miniMACS Introduction 12 User Manual Enhanced miniMACS Start up Instructions 12 User Manual Enhanced miniMACS Glossary of Terms 12 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Spindle Spindle Tightening steps Tightening steps Displays the Tightening step dialogue in which you can set the parameters of a step Tightening steps Spindle 1 larget hi bo fso b Jin deg Haig te Each tightening cycle is built up of different control modes such as torque angle jog etc Mode can be selected from one of the following step types Torque Angle Delay DynaTork Delay End Angle End Jog End Torque End or Yield To determine the last step of a set the control mode in that step should be of End type Such steps are displayed with a horizontal line under the step to indicate the end of a tightening set ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 13 User Manual Enhanced miniMACS Introduction 13 User Manual Enhanced miniMACS S
21. in an EEPROM memory The parameters are as follows Param SignatNeme peser o Sample time for traces default 1ms 0 10 Report Parameters After a set is completed a number of data will be available for retrieval by the Station Controller The retrieval is initiated by creating a report through marking ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 97 User Manual Enhanced miniMACS Introduction 97 User Manual Enhanced miniMACS Start up Instructions 97 User Manual Enhanced miniMACS Glossary of Terms 97 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com a step in a set with a report tag as detailed in 2 3 3 Spindle When a step fails a report is always created The report consists of 22 parameters numbered from 1 to 22 The first 10 parameter values represent the status and the result of the tightening cycle Parameters number 11 through 22 represent the EUN code par11 18 and the StartTime par19 22 The EUN code and the StartTime were transferred to the drive units together with the control input data over the Profibus interface as described in 7 3 1 Control Input Data Parameters 1 through 10 are as follows Par1 StepNumber The number of the reported step can differ from the report marked step when a step fails Par2 StepStatus The status of the reported step bit masked information on what went wrong see below ReportTorqu The actual
22. management It also co ordinates transferring of quantitative cycle data between the WinQCM E and the servos To use the Station Controller together with a particular tightening set up defined using the WinQCM E a number of parameters must be set up in the Station Controller application before it will work properly The most important is the parameter NoOfSpindles which defines the number of spindles controlled by the station but there are also a number of parameters that controls handling of reject management see 4 4 Reject management The Station Controller application program must be modified with the correct value of these parameters and be recompiled using the OpenControl development environment The parameters may also be set using the OpenControl Monitor but then the values need to be set whenever the Monitor is restarted The execution of the station is controlled by an external controller e g a PLC or Automation PC using the input and outputs signals described in section 4 5 Interface to the Automation PC A typical sequence performed by the Station Controller looks like the following 1 The Automation PC sets up the EUN code for the piece to be operated on inhibit any spindles that should not be used and defines the tightening set that should be used 2 The Automation PC starts the tightening cycle by raising the Start signal 3 The Station Controller checks that the system i e FBU and servos spindles involved is OK
23. one step at a time for each start signal set this input to logic one Mainly used in test and start up situations Inhibit Logic one will inhibit a start of a tightening cycle Set the input to logic zero to enable start fees SSOSCSCSCSCSCS Set Select 0 1st bit with weight 1 in the address word for selecting a program set Set Select 1 2 4 bit with weight 2 in the address word for selecting a program set Set Select 2 3 bit with weight 4 in the address word for selecting a program set Set Select 3 4 bit with weight 8 in the address word for selecting a program set Set Select 4 5th bit with weight 16 in the address word for selecting a program set ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 94 User Manual Enhanced miniMACS Introduction 94 User Manual Enhanced miniMACS Start up Instructions 94 User Manual Enhanced miniMACS Glossary of Terms 94 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 5 32 Set Select 5 6th bit with weight 32 in the address word for selecting a program set C e fepe S rete Qualitative Output Data Each servo drive unit continuously updates an output buffer of 4 bytes with its cycle status The FBU retrieves these data once every 100ms from all the drive units over the Lan1 bus and combines all data in its Profibus output buffer Since up to 40 drive units can be connected in the same
24. reset Time out Error Set high if the maximum time out time parameter for a step is exceeded for a step executed If set it remains high until the system is reset or the next cycle is started Transducer Measure Error Set high if and when the servo spindle detects a calibration error an offset error or an overflow error If set it remains high until the system is reset DC Bus Low Set high when the DC Bus voltage drops below the critical level If set it remains high until the system is reset ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 56 User Manual Enhanced miniMACS Introduction 56 User Manual Enhanced miniMACS Start up Instructions 56 User Manual Enhanced miniMACS Glossary of Terms 56 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Timing diagram for a typical case This timing diagram shows the valid time for signals and should be used as a help to understand how the enhanced miniMACS system works The diagram does not intend to reflect the absolute timing but more the order in which signal are set All outputs are valid when the Running signal goes low They will remain as set until a new start or a reset command is issued ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 57 User Manual Enhanced miniMACS Introduction 57 User Manual Enhanced miniMACS Start up Instructions 57 User Manual Enhanced miniM
25. software and press OK to download You can monitor the download status at the bottom left of screen Type FSTORE to store new file in Servo memory Type RESET SYSTEM to reset system Servo software will now restart again This always resets the node address to 1 If you want to be certain that the downloaded version is the correct one continue with the following Type CTRL Z 1 Wait for response of servo select Controller Force terminal mode from menu then type DISP EEPROM 63 and hit ENTER As a result the version of the servo application software will be displayed It will look similar to the following 1999220401 D ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 74 User Manual Enhanced miniMACS Introduction 74 User Manual Enhanced miniMACS Start up Instructions 74 User Manual Enhanced miniMACS Glossary of Terms 74 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com software we must use hexadecimal notation Therefore 1 15 will be 1 F hexadecimal Type CTRL Z 1 Then select Controller Force terminal mode from menu and wait until the servo displays its address Type CTRL C CTRL C to stop the servo software 14 Type EEPROM 6 241 for servo address 1 242 for servo address 2 etc Note 241 240 Node 240 1 See also the servo adress table below Type RUN3 to st
26. status still be NOK after the re tightening cycle then there is a programmable choice to either back off all spindles the remaining NOK spindles or to leave the joint as it is Group Based Reject Management When running Group Based Reject Management the following additional parameters must be defined in the Station Controller e RM_NoOfGroups Defines how many groups the spindles are divided into e RM_MaxNoOfFailedSpInGroupxx Defines how many spindles that may be faulty in group xx before the remaining spindles in the group are stopped e RM_GroupNoFor_Spxx Defines to which group spindle xx belongs The set specific parameter SetX_RM_MaxFailedSpindles is used also when running group based RM In this case it only defines how many spindles that may be faulty regardless of group belonging while still only the faulty spindles will be backed when executing the Back Off set Note When using group based reject management all normal tightening sets must have a Delay End step as the last step in the set Group based reject management operates as follows e All steps are executed synchronously by all spindles i e the next step is not started on any spindle until the current step is finished by all spindles Whenever a step is finished on all spindles the Station Controller checks how many spindles that report NOK in each of the groups This number is compared to the value of the parameter RM_MaxNoOfFailedSpInGroupxx e lf itis less or
27. the cycle data EUN Cycle Start Time Set number etc and triggers the WinQCM E to fetch the rest of the data needed directly from the servos If the cycle was found OK when evaluated then the tightening cycle is ended The station output OK is set high Running is set low and the state of the Station Controller is changed to Waiting for start If the cycle was found NOK and there is a valid reject management back off set defined for the set then reject management is started This is indicated by setting the station output RM back off started high and changing the state of the Station Controller to RM back off If the cycle was found NOK and no back off set is defined then the tightening cycle is ended The station output NOK is set high Running is set low and the state of the Station Controller is changed to Waiting for start ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 60 User Manual Enhanced miniMACS Introduction 60 User Manual Enhanced miniMACS Start up Instructions 60 User Manual Enhanced miniMACS Glossary of Terms 60 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com If the cycle is not finished and no error is indicated then the controller just starts the execution of the next step State RM back off The Station Controller enters this state when the first phase of reject management is started i e the execution of the
28. torque that was reached during the reported step e Peas Notes OOOO y eae nosa OOO Par nosa OOOO O SSSSOS S CSOSOSSCC Fas nosa OOO O SSSOSC SOSSSCSCSY Parameter 2 StepStatus holds the following information CC o Timeout Tmeoutexceeded O otwsed Od OSOSCSCSCSCSSSCSCSCSCSCSCSC C t Y Rotwsed id OSOSOSOSCSOSOSCSCSCSCSCSC S s Offset error Torque measurement offset too big checked when starting a set Noted OOCOCOCOCOCCCCC SNCC CY ASYQSW99085_202v6 doc 2000 06 20 ee Calibration error Torque measurement out of calibration checked when starting a set User Manual Enhanced miniMACS Contents 98 User Manual Enhanced miniMACS Introduction 98 User Manual Enhanced miniMACS Start up Instructions 98 User Manual Enhanced miniMACS Glossary of Terms 98 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com w posa po w fosa id OOSCSCSCSCSC C lt CSt d a fosa i SOSCSCSCSC COS fis ose sd OOSCSCSCSCSSTCY ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 99 User Manual Enhanced miniMACS Introduction 99 User Manual Enhanced miniMACS Start up Instructions 99 User Manual Enhanced miniMACS Glossary of Terms 99 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Trace Parameters Each tightening set is recorded into a
29. trace buffer The angle and torque values are sampled with 1kHz parameter 7 TraceT of the spindle parameters in 7 4 2 Spindle Parameters sets the sampling rate and pushed onto the buffer Each buffer has 2047 positions and if more samples are pushed the oldest will be lost The system supports 20 trace buffers Buffer 1 through 10 holds the latest OK NOK cycle recordings while trace buffers 11 through 20 holds the latest NOK cycle recordings When a new cycle starts the oldest trace buffer will be overwritten and called number 1 Trace buffer number 2 then holds the previous cycle recording If a tightening cycle fails trace number 1 which have just been recorded will be copied to buffer 11 The header of each buffer will contain the following data Nr of samples max 2047 TraceT sample rate SpindleNo 1 40 Stepstatus EUN code StartTime ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 100 User Manual Enhanced miniMACS Introduction 100 User Manual Enhanced miniMACS Start up Instructions 100 User Manual Enhanced miniMACS Glossary of Terms 100 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com References References miniMACS User s Manual Release 1 ASY 9834 0946 01 1997 02 2 CPU2 for Enhanced miniMACS Requirement ASY QSW99036 GF 990122 Specification QCM2 User s Manual 4 0 ACC 9032 0019 01a Feb 10 1999 Le GAN Spe
30. www artisantg com Then all currently not inhibited spindles are started The execution of the cycle and reporting to the WinQCM E are controlled the same way as for the states Running Back off and Re tightening except for that when the cycle is finished the following action is always taken e The tightening cycle is ended The station output NOK is set high Running is set low and the state of the Station Controller is changed to Waiting for start ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 63 User Manual Enhanced miniMACS Introduction 63 User Manual Enhanced miniMACS Start up Instructions 63 User Manual Enhanced miniMACS Glossary of Terms 63 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Interface of the manual Station Controller The standard versions interface to the overriding Automation PC is for the manual version replaced by a discrete digital I O interface The I O modules are interfaced to as Profibus slaves on the same Profibus link as the FBU is connected to Depending on the number of spindles included in the station up to four I O modules are used They are used as follows e Module 1 Profibus slave node 4 Includes the station general signals Start Stop parameter set etc and the spindle specific inputs and outputs for the first nine spindles e Module 2 Profibus slave node 5 Coops with the inputs and outputs o
31. 085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 96 User Manual Enhanced miniMACS Introduction 96 User Manual Enhanced miniMACS Start up Instructions 96 User Manual Enhanced miniMACS Glossary of Terms 96 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com e T_trig Nm 10 Target value for torque steps For yield steps this is the level where the reference slope is measured T_max Nm 10 Max level for torque alarm level T_min Nm 10 Min level for torque alarm level For yield steps this is the relative trig level on the slope Speed rpm signed Speed set point for all steps s A_trig degrees Target value for angle steps For yield steps this is the base angle for slope calculations s e A max degrees Max level for angle alarm level s e A_min degrees Min level for angle alarm level e Delay 1 10sec Delay time for delay steps For all other steps this is a start delay currently the later function is not implemented in the WinQCM E e Timeout sec Timeout for all steps If a limiting parameter is set to zero that limit will not be checked i e no fault trips will occur Spindle Parameters For proper operation the servo drive unit needs to know the characteristics of the spindle it is supposed to operate The spindle characteristics are defined in 15 parameters numbered from 1 to 15 In the servo drive unit the parameters are stored internally
32. 5 User Manual Enhanced miniMACS Glossary of Terms 105 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com A rtisan Artisan Technology Group is your source for quality TecmoogyGroup new and certified used pre owned equipment FAST SHIPPING AND SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT DELIVERY Experienced engineers and technicians on staff Sell your excess underutilized and idle used equipment TENS OF THOUSANDS OF at our full service in house repair center We also offer credit for buy backs and trade ins IN STOCK ITEMS www artisantg com WeBuyEquipment 7 EQUIPMENT DEMOS HUNDREDS OF InstraV ea REMOTE INSPECTION LOOKING FOR MORE INFORMATION MANUFACTURERS Remotely inspect equipment before purchasing with Visit us on the web at www artisantg com 7 for more our interactive website at www instraview com information on price quotations drivers technical LEASING MONTHLY specifications manuals and documentation RENTALS ITAR CERTIFIED D a gaa tia Contact us 888 88 SOURCE sales artisantg com www artisantg com
33. 82 User Manual Enhanced miniMACS Introduction 82 User Manual Enhanced miniMACS Start up Instructions 82 User Manual Enhanced miniMACS Glossary of Terms 82 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com By placing a short cut to the OpenControl Monitor in the Autostart group the PC can then be configured to automatically start the Station Controller whenever the PC is started To do that do the following e Create a shortcut to the OpenControl monitor OCM EXE in C WINNT Profiles All Users Start Menu Programs Autostart The file OCM EXE is normally found in the directory C Program Files Nemasoft OpenControl e Edit the properties of the shortcut by adding ApSC_v_1_4 to the field labelled Target Shortcut to OCM exe Properties 21x General Shortcut Security gt Shortcut to OCM exe Target type Application Target location OpenControl Target Jes Nemas oft OpenControl OCM exe ApSC_v_1_4 M Ronin separate Memon space Start in C Program Files NemaSoft OpenControl Shortcut Key IN one Bun Normal window x Find Target Change Icon ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 83 User Manual Enhanced miniMACS Introduction 83 User Manual Enhanced miniMACS Start up Instructions 83 User Manual Enhanced miniMACS Glossary of Terms 83 Artisan Technology Group Quality Instrumentati
34. ACS Glossary of Terms 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 4 Appendix 4 QCM2 CAN Communication 8 References 8 1 References 9 Glossary of Terms ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 4 User Manual Enhanced miniMACS Introduction 4 User Manual Enhanced miniMACS Start up Instructions 4 User Manual Enhanced miniMACS Glossary of Terms 4 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Introduction Overview This manual describes the functionality of the enhanced miniMACS system The system consists of the following physical or functional parts e The miniMACS PC e Field Bus Unit FBU e QCM2 QCS82 Servo Drive Units The miniMACS PC consists of three parts the WinQCM E GUI the Station Controller and a MMS interface WinQCM E is the tool used to configure the servos including the tightening programs used WinQCM E is an enhanced version of the WinQCM 81 43 The Station Controller is responsible for the co ordination of the individual servos in order to make them act as a unit It mainly handles start and stop of a cycle and possible reject management actions In order to achieve real time performance the Station Controller is implemented using OpenControl OpenControl provides a framework to program and run machine control applications on Windows NT system See Ref
35. ACS Glossary of Terms 57 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The logic of the Station Controller The Station Controller can be described as a state machine with following states and transitions The actions taken in the different states are described in the following sections State Idle The system is under initialisation The Station Controller enters this state only once and that is when the OpenControl Monitor starts the Station Controller application Here some global data are set and the servos spindles are initialised The next state is always Waiting for start ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 58 User Manual Enhanced miniMACS Introduction 58 User Manual Enhanced miniMACS Start up Instructions 58 User Manual Enhanced miniMACS Glossary of Terms 58 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com State Waiting for start In this state the Station Controller is ready to start a new tightening cycle It continuously scans the reset and start signals looking for a positive edge on either of them If a Reset order is detected then all Station Controller outputs are cleared and all servos are reset by generating a low pulse on the FBU input Controller On the timer ResetTimer controls the length of this pulse The Station Controller will in this case remain in the st
36. AD EOL lt SeqNo gt EOL lt NewRecord gt EOL lt StationName gt EOL lt EUN gt EOL lt Date gt EOL lt Time gt EOL lt SetNo gt EOL lt CycleResult gt EOL lt NoOfSpindles gt EOL SPINDLES EOL lt optSpindleList gt lt spindle gt lt optSpindleList gt NOTHING lt spindleNo gt HT lt finalTorque gt HT lt MinTorqueLimit gt HT lt MaxTorqueLimit gt HT lt finalAngle gt HI T lt MinAngle Limit gt HT lt MaxAngleLimit gt HT lt inibited gt HT lt Status gt EOL lt numStr gt a sequnce number 1 0 1 indicates that this cycle data is lt alphaNumStr gt name of the station lt alphaNumStr gt EUN code as supplied from the lt dateNumStr gt date when the cycle was started lt timeStr gt time when the cycle was started lt numStr gt set number executed for the cycle OK NOK overall cycle result lt numStr gt number of spindles in the station lt TimeOutExc lt numStr gt the spindle number lt floatStr gt the final torque reported for the lt floatStr gt min allowed torque lt floatStr gt max allowed torque lt floatStr gt the final angle reported for the lt floatStr gt min allowed angle lt floatStr gt max allowed angle 1 0 1 indicates that spindle was ASYQSW99085_202v6 doc 2000 06 20 Contents 45 Introduction 45 User Manual Enhanced miniMACS Start up Instructions 45 Glossary of Terms 45
37. All servos spindles will be machine stopped This signal has precedence over all other input signals Link alive This signal is optional If the parameter SuperviseAPCLink is set to one 1 the Station Controller uses this signal to supervise the connection to the Automation PC If found 0 zero the station will be stopped Reset A positive edge on this signal resets the system i e the station controller logic as well as all servos spindles While the system is running indicated by the output signal Running new reset commands are ignored ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 54 User Manual Enhanced miniMACS Introduction 54 User Manual Enhanced miniMACS Start up Instructions 54 User Manual Enhanced miniMACS Glossary of Terms 54 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Outputs During and after a cycle the Station Controller indicate its status using the following output signals items printed in italic on grey background are optional and may be used if so wanted Signal Description o Running This signal is high when the station is executing a tightening cycle While this signal is high all inputs but stop are neglected When Running goes low the output signals are valid RM back off started This signal is set high when a back off set is started If set it will remain high during the rest of the tightening cycle See
38. C Data for SPC is collected for all spindle cycles with OK status Data are collected only for those variables that have been set up using the SPC Set up function Data are collected in two main ways e as subgroups e as latest results When data are collected into subgroups data from a specified number of samples are used to calculate Average and Range or Standard deviation which are saved for the subgroup The original values are automatically deleted This is repeated with a selectable frequency either specified in number of samples or in time between start of subgroups If frequency is specified in time a subgroup is discarded if it is not complete within 30 minutes For a detailed view of the latest samples there is also a buffer for latest results This contains all the latest samples but for a much shorter period of time Which variables to collect are set up uniquely for each spindle and set The data currently collected and held by the SPC module is saved to disk whenever it is updated See Appendix 1 SPC Calculations for a description on how the SPC data is calculated ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 28 User Manual Enhanced miniMACS Introduction 28 User Manual Enhanced miniMACS Start up Instructions 28 User Manual Enhanced miniMACS Glossary of Terms 28 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Set up Use
39. CS Contents 103 User Manual Enhanced miniMACS Introduction 103 User Manual Enhanced miniMACS Start up Instructions 103 User Manual Enhanced miniMACS Glossary of Terms 103 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Graphical User Interface 1 0 Input Output IGAIN Integral gain for controller INC Increment LAN Local Area Network LTL Lower Tolerance Limit MMS Manufacturing Message Standard PC Personal Computer PGAIN Proportional gain for controller PLC Programmable Logic Controller Rdy Short for Ready RM Reject Management sl Standard deviation lower limit SPC Statistic Process Control su Standard deviation upper limit TC Torque slope reference The torque value used as reference value for when executing a Yield step ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 104 User Manual Enhanced miniMACS Introduction 104 User Manual Enhanced miniMACS Start up Instructions 104 User Manual Enhanced miniMACS Glossary of Terms 104 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com TDA Trend Deviation Analysis UPS Un interruptible Power Supply UTL Upper Tolerance Limit ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 105 User Manual Enhanced miniMACS Introduction 105 User Manual Enhanced miniMACS Start up Instructions 10
40. Control Panel E Control Panel OF x File Edit View Go Favorites Help rn 2 amp Back Fonvard Up Cut Copy E r BS PROFIBUS CAN Hardware Console Date Time 1 object s selected 3 My Computer NOTE Do not modify any setting for this driver unless you really know what you are doing Erroneous settings may cause malfunction If you still choose to make modifications here make ABSOLUTELY SURE that you do not include the slave board used for the communication with Automation PC in the count of boards l e the value specified in the field Boards below should ONLY state the number boards to be used as Profibus DP masters The reason for this is that the device driver will automatically download DP master firmware to all boards specified here To make a board behave as a DP slave it must be configured with special firmware This must be done manually using special software Please contact Atlas Copco Assembly Systems for instructions on how to do this PROFIBUS x Boards 1 i Board Type PROFlboard ti 10 Port 0 240 v DPRAM Address OxDOO00 Y Interrupt 11 hi ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 77 User Manual Enhanced miniMACS Introduction 77 User Manual Enhanced miniMACS Start up Instructions 77 User Manual Enhanced miniMACS Glossary of Terms 77 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com
41. E www artisantg com During this sequence the Station Controller continuously reports its status All sets are executed in a synchronised manner i e the execution of a step is not started for any of the spindles until all spindles have finished executing the previous step The execution of any on going tightening cycle is immediately terminated if the Automation PC raises the Stop signal If a spindle indicates an error not classified as a tightening related error it must be reset Generating a positive edge on the Reset input does this The Station Controller will control how the WinQCM E reports data in its Result window see 2 2 1 The Results Window so that it always present the result of the last tightening cycle even if the tightening cycle is ended by running a back off set See 4 6 The logic of the Station Controller for a more detailed description of operations of the Station Controller Reject management All reject management is based on executing special sets for the back off and re tightening cycles when the ordinary cycle fails You can choose between three types of reject management Standard RM Group based RM and Group based RM with priority The basic difference between them is the condition for when a RM action is started When running Standard RM all spindles are monitored as a single group and the reject management action is started when the total number of faulty spindles are greater than a value specified f
42. K must indicate the servo drive running properly relay contacts closed at connector K7B 35 36 at the time Controller On is set to logic one The internal computer reads the transition from one logic level to the other 2 4 Cycle Stop Logic one will stop the tightening step in progress and put the servo drive in status OK if the control mode for the step is of type END If the control mode for the step is of type Con for continue the next step program will be started No other operations are involved Designed with for instance positioning tasks in mind A limit switch can be used for the Cycle Stop input 3 Start Set the input to logic one to start a tightening cycle beginning with the step program selected by the address on Select 1 2 4 8 16 32 and ending with the step program containing the control mode END The input signal Controller ON has to be set to logic one green LED Rdy is lit before the Start signal is activated ae ail Rei Pa ae ae mk Lear ae La Step Sync IN Logic one will inhibit a start of a tightening step Set the input to logic zero to enable start Use the input in conjunction with the Step Sync OUT output signal from the same servo drive or a combination of several drives Step Mode Set the input to logic zero to have a complete cycle with several steps run for each start signal normal mode If you want the servo drive to run only
43. RM_BackOffSet MUB5 0 No F ZMR 64 Bit Long Real Set _RM_ReTighteninaSet MUBB 0 No gt Setl_RM_2ndFailureAction MUB7 0 No 7 Seared ragen Setl_RM_2ndFailureSet MUBB 0 No F ZMW A Bit oa MUBS 0 No i 2M Bits Set2_RM_MazFailSpindles 4MUB10 0 No Motion Set2_RM_BackOffSet MUBI1 0 No Outputs ZMUB12 Set2_RM_ReTighteningSet MUB12 0 No RF Tags Set2_RM_2ndFailureAction MUBI3 0 No 7 AMUs Set2_RM_2ndFailureSet 4MUB14 0 No Strings MUB15 0 No 7 Timers Set3_RM_MazFailedSpindles MUBIEB 0 No ProfiBus Configurator Set3_RM_BackOffSet MUBI 0 No 7 Set3_RM_ReTighteningSet MUBI8 0 No Set3_RM_2ndFailureAction MUB19 0 No MUB20 Set3_RM_2ndFailureSet MUB20 0 No MUB21 MUB21 0 No 7 Set4_RM_MazFailedSpindles MUB22 0 No 7 Set4_RM_BackOffSet MUB23 0 No Set4_RM_RetTighteningSet MUB24 0 No 7 Set4_RM_2ndFailureAction MUB25 0 No m Set4_RM_2ndFailureSet 4MUB26 0 No i 7 om OpenControl 4 3 Ready x RRs 7 e Inthe left panel select the item Logic Memory Memory MUB 8 Bit Unsigned e Inthe right panel Locate the parameters name in column Alias and set the correct value in column Initial Value e Select the menu item File Save Recompilation After giving the parameters above appropriate values the application must be recompiled Note If you do not have a dongle that enables the development environment you should not recompile the application It would create a runtime v
44. Reject Management for a description of back off RM re tightening started This signal is set high when a re tightening set is started If set it will remain high during the rest of the tightening cycle See Reject Management for a description of re tightening This signal is low when a tightening cycle is started and is set high if it finishes without any errors This signal is low when a tightening cycle is started and is set high if it finishes with an error Communication error This bit is set high when the communication with the FBU fails or when the FBU fails to communicate with any of its spindles This signal is set high if all spindles reports that the DC bus is low Parameter set failure This signal is set high if the all spindles do not confirm the ordered set number The evaluation is done when all spindles have started the execution of the cycle This time is normally within 200 300 ms from that a start command is issued Note that the set number confirmed by the spindles also is evaluated when any reject management cycle is started This means that this signal may be set in the middle of a tightening cycle Confirmed set number This signal four bits is the set number confirmed by all the spindles if they all confirm the same set number If not this signal remains set to zero 0 and the signal Parameter set failure is set high Stopped This signal is optional Is set high if the Station Controller is stopped du
45. S Contents 61 User Manual Enhanced miniMACS Introduction 61 User Manual Enhanced miniMACS Start up Instructions 61 User Manual Enhanced miniMACS Glossary of Terms 61 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com State RM re tightening The Station Controller enters this state when the second phase of reject management is started i e the execution of the re tightening set When state is entered the servos are prepared to run the re tightening set on all spindles that where backed The servos are therefore set up with the following the number of set to re tighten with the original EUN code a new cycle start time and the same inhibit information as set up for the execution of the back off set Then all currently not inhibited spindles are started The execution of the cycle and reporting to the WinQCM E are controlled the same way as for the states Running and Back off except for that when the re tightening cycle is finished the following actions are taken depending on how it ends If the re tightening cycle was found OK then the tightening cycle is ended The station output OK is set high Running is set low and the state of the Station Controller is changed to Waiting for start If the re tightening cycle was found NOK when evaluated and the 2 failure action is set to either back off all or the currently NOK spindles then reject management continues with the
46. User Manual Enhanced miniMACS Glossary of Terms 91 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Appendix 3 FBU Profibus interface The Station Controller controls the tightening system over a Profibus DP interface The control input data is sent from the Station Controller over the Profibus DP interface to the FBU where the signals are unpacked and distributed to all servo drive units over the Lan1 bus Qualitative output data or cycle status i e Running OK NOK from all drive units are continuously retrieved by the FBU and sent to the Station Controller over the Profibus DP interface For a more detailed description of the Profibus DP interface see Ref 05 Control Input Data The Profibus output buffer of the Station Controller and the Profibus input buffer of the FBU each holds 41 bytes of data As soon as any value in the Station Controller buffer changes the complete 41 bytes are sent over the Profibus to update the FBU buffer The buffers hold the following data 16 24 Noted o o O ion below oa Start Time byte 6 See description below ASYQSW99085_202v6 doc 2000 06 20 EUN Julian day Character 12 of the EUN code Start Time byte 1 See description below User Manual Enhanced miniMACS Contents 92 User Manual Enhanced miniMACS Introduction 92 User Manual Enhanced miniMACS Start up Instructions 92 User Manual Enhanced miniMACS Glossary of Terms 92 Ar
47. _BackOffSet The number of the set that will be used to back off the spindles e Setxx_RM_ReTighteningSet The number of the set that will be used re tighten the spindles Usually the same as the normal tightening set e Setxx_RM_2ndFailureAction The second failure action O leave the joint as itis 1 back off the remaining NOK spindles and 2 back off all spindles e Setxx_RM_2ndFailureSet The number of the set that will be used to back off the spindles during the second failure action The above four parameters all have the value zero 0 by default and must be set to correct values before running the station See 6 4 2 Setting the OpenControl parameters for how to do this Note From statistical point of view SPC Reject Report etc all cycles are treated the same This means that cycle data generated when executing a reject management set is recorded just as any for any other cycle However different set numbers may distinguish them Standard Reject Management Standard Reject management operates as follows e All steps are executed synchronously by all spindles i e the next step is not started on any spindle until the current step is finished by all spindles Whenever a step is finished on all spindles the Station Controller checks how many spindles that currently report NOK This number is compared to the value of the parameter Max number of failed spindles to allow only the failed spindles to be backed e If itis le
48. al tightening set is executed The first thing done is to initialise all not inhibited servos with the EUN code Set number and cycle start time according to the sampled value of the corresponding input values Secondly the servos spindles are ordered to start the execution of the cycle The Station Controller then supervises that all servos begin to execute the cycle within 1000 ms If this fails then the on going cycle is terminated by machine stopping all spindles If the cycle is started on all servos within the given time then the set number confirmed by each of them is read back and compared against the ordered one If an erroneous set number is detected then the output signal Confirmed set number is set high and the on going cycle is terminated by machine stopping all spindles The Station Controller then continuously scans the status of all the spindles participating in the cycle in order to detect when they all have finished to execute the on going step When that is the case it checks whether or not the cycle is finished and how many of the spindles executed during this cycle for which an error is reported If this number is greater than what is allowed set by the reject management parameter MaxFailedSpindles for the set then the on going cycle is terminated by machine stopping all servos If the cycle is finished the Station Controller evaluates the result of the cycle It then supplies the WinQCM E with parts of
49. an be displayed with use of the Select button When pressed the following form is displayed Select Trace y Psor E 1970 01 01 00 00 00 01234 4990015678 My Comment 1 1999 04 22 20 51 48 3 2 Ky Comment 2 1999 05 10 12 59 23 01234 4990015678 My Comment 3 The list shows all traces that are stored By use of the controls in the Show traces for frame you can filter out which traces to show The EUN code entered may start and or end with the wild character Only the traces with an EUN that matches the entered value will be displayed ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 35 User Manual Enhanced miniMACS Introduction 35 User Manual Enhanced miniMACS Start up Instructions 35 User Manual Enhanced miniMACS Glossary of Terms 35 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Report File View Spindle Setup Loadparameters Accesslevel SPC Trace MMS Help Jec Define End of shift View Reject This function invokes the Reject Report window which presents a reject report based on the last 1000 cycles The data collected for each NOK cycle is stored on disk Percentage of NOK cycles 40 27 2000 04 27 10 16 42 SeqNo 14115 Set 2 EUN 01234 A990015678 Sp 1 Step 6 OK Sp 2 Step 8 NOK Timeout 2000 04 27 10 16 57 SeqWo 14116 Set 2 EUN 01234 4990015678 Sp 1 Step 0 Inhibited OK Sp 2 Step 7 NOK Timeout
50. artup servo software with new node number Unplug the PC the Servo is now set up Goto Next Servo Servo address table Servo or FBU Eeprom 6 Hex number Value Address O 0 2 0 O 11631 241 1 2317 32 22 2 Pp 318 w 3 O s9 m 4 n 52 25 5 O 62n 26 6 Pp 823 28 8 O S24 29 P1426 2351 B o 1328 253 D 1a Setup correct servo address Servos are addressed 1 15 starting from the left most servo going right When specifying the servo address using ECT Down load FBU Software Copy the FBU application software HEE to the directory ATLAS FBU Then do the following Setup FBU address and load down software into FBU Plug PC into host port on front of FBU Load the FBU application software onto PC hard drive this is FBU software Select Window Terminal you are now in terminal mode Make sure FBU is powered up ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 75 User Manual Enhanced miniMACS Introduction 75 User Manual Enhanced miniMACS Start up Instructions 75 User Manual Enhanced miniMACS Glossary of Terms 75 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com communication with selected unit Then select Controller Force terminal mode and wait until FBU displays its address e g gt for address 0 1 gt for address 1 etc 7 Download FBU software Select
51. at it finished with a NOK result 11 Running or NOK Spindle 4 A high value indicates that the spindle either is running or that it finished with a NOK result 12 Running or NOK Spindle 5 A high value indicates that the spindle either is running or that it finished with a NOK result 13 Running or NOK Spindle 6 A high value indicates that the spindle either is running or that it finished with a NOK result 14 Running or NOK Spindle 7 A high value indicates that the spindle either is running or that it finished with a NOK result 15 Running or NOK Spindle 8 A high value indicates that the spindle either is running or that it finished with a NOK result 16 Running or NOK Spindle 9 A high value indicates that the spindle either is running or that it finished with a NOK result ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 66 User Manual Enhanced miniMACS Introduction 66 User Manual Enhanced miniMACS Start up Instructions 66 User Manual Enhanced miniMACS Glossary of Terms 66 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Module 2 1 Group 1 OK Set high if all spindles included in group 1 finished the tightening cycle OK See 4 4 2 Group Based Reject Management for a description of groups 2 Group 1 NOK Set high if any of the spindles included in group 1 finished the tightening cycle NOK 3 Group 2 OK Set high if all spindles included in group 2 finished the t
52. ate Waiting for start If a Start order is detected the Station Controller will change state to Checking Spindles State Checking spindles In this state the Station Controller checks for any error that should cancel a start It checks that e the communication with the FBU is OK e the communication between the FBU and all not inhibited spindles is OK e all not inhibited servos spindles report Controller OK and non of the following General Hardware error DC Bus down and Cycle Running If all conditions are found to be OK then following takes place e the value of the input signals EUN code Set number and Inhibit are sampled and stored e all Station Controller outputs are cleared e the output signal Running is set high and the Station Controller changes its state to Running If an error is found then the start is cancelled and the state is changed to Waiting for start The station output Communication error and or the corresponding output signals for each spindle indicate the error or errors that caused the cancelling ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 59 User Manual Enhanced miniMACS Introduction 59 User Manual Enhanced miniMACS Start up Instructions 59 User Manual Enhanced miniMACS Glossary of Terms 59 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com State Running The Station Controller is in this state while the norm
53. atistics window which displays the statistical curves calculated by the SPC In the upper right corner you select which type of display you want e Average and Standard Deviation Range curves e Ditto for Short Term Trend e Histogram Select the variable you want to study with the controls Spindle Set and Variable When a selection is made the curves for Average and Standard deviation or Range ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 30 User Manual Enhanced miniMACS Introduction 30 User Manual Enhanced miniMACS Start up Instructions 30 User Manual Enhanced miniMACS Glossary of Terms 30 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com SPC Statistics x Station sati_2sp J Setno ff m i Spindleno fi 7 Variable Toque im A ay Trend istogram Average UCL 031 LCL 0 04 Mean 013 Cp 649 Cpk 6 05 Standard Deviation eile nee Mean 0 09 FSdev 0 27 3 Sdev 0 27 Si 2 Clear Data pelete er Print Refresh are plotted for the variable in question To the left the current values of e g Cp and Cpk are displayed These values are either calculated on the SPC and TDA data buffer or the short term trend buffer dependent on the current selection in the form If you find a subgroup in the SPC and TDA buffer which have an abnormal value you can delete it Click in the diagram on the subgroup you want t
54. back off set When state is entered the servos are prepared to run the back off set This is done as follows e if the normal cycle state Running resulted in that the number of failed spindles was less or equal to the parameter MaxFailedSpindles then all OK spindles are inhibited This is done to ensure that only the NOK spindles are backed in this case Otherwise all spindles are backed off See also Reject management e the number of set to back off with the original EUN code and a new cycle start time is sent to the servos Then all currently not inhibited spindles are started The execution of the cycle and reporting to the WinQCM E are controlled the same way as for the state Running except for that when the back off cycle is finished different actions are taken depending on how it ends If the back off cycle was found OK when evaluated and there is a valid re tightening set defined for the original set then reject management continues with the re tightening phase This is indicated by setting the station output RM re tightening started high and changing the state of the Station Controller to RM back off If the back off cycle was found NOK or if no re tightening set is defined then the tightening cycle is ended The station output NOK is set high Running is set low and the state of the Station Controller is changed to Waiting for start ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMAC
55. ced miniMACS Contents 65 User Manual Enhanced miniMACS Introduction 65 User Manual Enhanced miniMACS Start up Instructions 65 User Manual Enhanced miniMACS Glossary of Terms 65 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Outputs Module 1 1 Station OK Set high if a tightening cycle finished OK See also description of signal OK in section 4 5 2 Outputs 2 Station NOK Set high if a tightening cycle finished NOK See also description of signal NOK in section 4 5 2 Outputs 3 Running Set high when the station is running a cycle See also section 4 5 2 Outputs 4 System OK Set low if any of the following is detected Emergency Stop FBU Servo communication error Set No error Comm error with any of the I O modules When set low it remains low until a Reset or Start is detected 5 Confirmed Parameter Bit 0 Confirmation of ordered tightening set Binary bit 0 value 1 Confirmed Parameter Bit 1 Confirmation of ordered tightening set Binary bit 1 value 2 7 Confirmed Parameter Bit 2 Confirmation of ordered tightening set Binary bit 2 value 4 Running or NOK Spindle 1 A high value indicates that the spindle either is running or that it finished with a NOK result Running or NOK Spindle 2 A high value indicates that the spindle either is running or that it finished with a NOK result 10 Running or NOK Spindle 3 A high value indicates that the spindle either is running or th
56. ciicaion asv asweoniarom Sep 17 1000 8 OpenContol User Gude Version 3 Nores ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 101 User Manual Enhanced miniMACS Introduction 101 User Manual Enhanced miniMACS Start up Instructions 101 User Manual Enhanced miniMACS Glossary of Terms 101 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com This page is intentionally left blank ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 102 User Manual Enhanced miniMACS Introduction 102 User Manual Enhanced miniMACS Start up Instructions 102 User Manual Enhanced miniMACS Glossary of Terms 102 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Glossary of Terms BNF Backus Naur Form A notation commonly used for describing context free grammars CAN Controller Area Network Con Short for Continue Cp Process capability Cpk Process capability including spread CPU Central Processing Unit DC BUS Directed Current Bus DGAIN Proportional gain for controller ECT Edit Compile Test Development environment for the DMC servos EOL End Of Line An ASCII character marking the end of a line of text E Stop Emergency stop EUN Engine Unit Number FBU Field Bus Unit ft Ib Foot Pound libra GUI ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMA
57. could look like this e A start command is sent from the Station Controller to the FBU through the Profibus interface The FBU processes the data and transfers the start command to the servo drive units through the Lan1 bus Each drive unit responds to the start command by setting status signals and performs the chosen tightening set The FBU retrieves status signals and qualitative data from all drive units through the Lan1 bus and transfers it back to the Station Controller through the Profibus interface e During the tightening cycle each drive unit stores quantitative tightening data in its internal register based memory as further described in chapter 5 4 1 When the tightening set is done the WinQCM E retrieves the quantitative tightening data from the servo drive units through the Lan2 bus This information is e g used for SPC Statistical Process Control calculations in the WinQCM E When the start signal is received the servo drive unit runs the motor according to a pre programmed operation sequence stored in its internal memory Each sequence or set contains one or more tightening steps where each step contains ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 69 User Manual Enhanced miniMACS Introduction 69 User Manual Enhanced miniMACS Start up Instructions 69 User Manual Enhanced miniMACS Glossary of Terms 69 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www art
58. e and how the cycle data displayed is formatted Satl_3sp qe1 WinQCM E OL x File View Spindle Setup Loadparameters Accesslevel SPC Trace Report MMS Help x ofe th BY ferne OFF LINE I Log WSC Aiast a 0K SPINDLES 4 1 0 0 10 0 360 0 0 0 0 0 0 0000000000011 0 0 0 0 0 0 0 0 0 0 0 0 1 0000000000000 1 3 0 0 10 0 360 0 0 0 0 0 0 0000000000011 HEAD 100 atl_3sp 01234 4990015678 2000 05 28 11 43 24 0K SPINDLES 4 1 0 0 10 0 360 0 0 0 0 0 0 0000000000011 0 0 0 0 0 0 0 0 0 0 0 0 1 0000000000000 1 3 0 0 10 0 360 0 0 0 0 0 0 0000000000011 w 4 gt Results Tightening cycles MMS CAP NUM 16 02 There are two options for which cycle data that can be displayed in this window e All cycles currently recorded in the MMS queue e All cycles currently recorded in the MMS queue that have not been read yet by the MMS server The data currently displayed can either be printed or saved to disk by using the menu alternative File Print or MMS Save ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 10 User Manual Enhanced miniMACS Introduction 10 User Manual Enhanced miniMACS Start up Instructions 10 User Manual Enhanced miniMACS Glossary of Terms 10 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Menus This section lists describes the functions that are available from the WinQCM E menu File View Spindle Setup L
59. e byte Request for all cycle data currently stored This telegram is sent to WinQCM from the MMS server when it wants all cycle data currently stored The telegram has the following format it has no message body lt telegram type gt 1 decimal ASCIl code 49 lt message body gt not valid ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 42 User Manual Enhanced miniMACS Introduction 42 User Manual Enhanced miniMACS Start up Instructions 42 User Manual Enhanced miniMACS Glossary of Terms 42 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Example STX 1 ETX or as decimal ASCII codes 02 49 03 WinQCM responds by sending one telegram for each cycle data currently stored The data for the oldest cycle will be sent first the second oldest is sent in the second telegram and so on until all cycles stored are transferred To indicate that all cycle data are transferred WinQCM sends an end of cycle data telegram If there are no cycle data recorded this is the only telegram sent Request for all cycles not currently read This telegram is sent to WinQCM from the MMS server when it wants the cycle data of all cycles recorded since the last request for cycle data The telegram has the following format it has no message body lt telegram type gt 2 decimal ASCIl code 50 lt message body gt not valid Example STX 2 ETX
60. e to that the Automation PC issued a Stop order Cycle Start Error This signal is optional Is set if all spindles did not report that they are running within the time defined by the CycleStartTimer 1000 ms FBU comm Error This signal is optional Is set high if the Station Controller have lost the contact with the FBU WinQCM overrun This signal is optional Is set high if the WinQCM did not finish reading cycle data within the time defined by the WinQCMTimer 3000 ms Spindle Comm Error This signal is optional Is set high if the FBU loose contact with one or more spindles NT crashed This signal is optional Is set high if NT crashes Ready for Start This signal is optional Is set high when the Station Controller accepts a new start order After that the signal Running goes low a new Start is not accepted until the WinQCM has finished ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 55 User Manual Enhanced miniMACS Introduction 55 User Manual Enhanced miniMACS Start up Instructions 55 User Manual Enhanced miniMACS Glossary of Terms 55 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com APC comm Error This signal is optional Is set high when the Station Controller has lost contact with the Automation PC Only active if supervision is enabled using one of the parameters StopSignallsNegated or SuperviseAPCLink Parameter Error This signal i
61. eating OpenControl database Loading logic solve Starting OpenControl Log Manager Synchronizing device driver s Logging to directory C Program Files NemaSoftiOpenControl iProjects SC_y _1_4 Log Loading device configuration s Be ProfiControl Version 4 03 504 Copyright ICT Inc 19961997 1998 Portions Copyright Softing GmbH 1996 19971998 Consult the license agreement provided for terms and conditions regarding your use of this product Starting PROFIBUS Configuration ProfiBus ProfiControl DP Slave Interface Version 4 03 404 Copyright ICT Inc 19961997 1998 Portions Copyright Softing GmbH 1996 19971998 Consult the license agreement provided for terms and conditions regarding your use of this product Starting PROFIBUS Configuration ProfiBus2 Starting user program s User program C Atlas UserProg GetTime exe started Initializing device hardware OpencCortrol Multiple Driver Execution Engine started fF 000000 000000 4 31PM 4 e Select the latest version of the Station Controller application e g SC_v_2_2 using the drop down combo box labelled Project Name e Ensure that the Execution Mode is set to Real e Press the Start button Auto start of the OpenControl Monitor By providing an argument to the OpenControl monitor when started it can automatically launch the Station Controller application started ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents
62. ed The number and percentage of NOK cycles executed since buffers where cleared The average 3 sigma Cp and Cpk for all variables currently set up to be monitored for SPC at the end of the shift These variables are calculated on the SPC and TDA data buffer Note The calculations of these variables are not reset when the other buffers are cleared e g at the start of a shift To set up when the end of shift reports should be printed select the menu alternative Report Define End of Shift It will cause the following form to be displayed Weekday Sunday 1 Monday 2 Tuesday 3 o Timeformat 00 00 23 59 aca Weekday Stat Stop Cancel Pa fi Print current Print previous MV Automatic clear at shift start last cleared at 2000 03 14 10 05 JV Automatic printout at shift end ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 37 User Manual Enhanced miniMACS Introduction 37 User Manual Enhanced miniMACS Start up Instructions 37 User Manual Enhanced miniMACS Glossary of Terms 37 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com In this dialogue you can define the start and end of each shift using a weekly calendar A shift that ends on another day than it starts on is defined using two rows in the grid The start time is defined on the first line with the stop time left blank The stop time is defined on the seco
63. equal the Station Controller will start the execution of the next step for all spindles that still have status OK in the corresponding group If it is greater then the on going cycle is terminated by machine stopping all spindles in the group This will cause all still OK spindles in the group to become NOK and report Machine Stop If Group based RM with priority is selected than all spindle belonging to groups with higher group numbers also are stopped e If the cycle finishes with status NOK i e at least one spindle failed the reject management function is activated e Based on the total number of NOK spindles in the station either all spindles or only the NOK spindles will be backed using the back off set If the back off cycle ends successfully the re tightening set will be used to re tighten the joints Should the back off cycle fail then the station will not try to run the specified re tightening set but stop and report NOK for the overall cycle e Should the station status still be NOK after the re tightening cycle then there is a programmable choice to either back off all spindles the remaining NOK spindles or to leave the joint as it is ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 53 User Manual Enhanced miniMACS Introduction 53 User Manual Enhanced miniMACS Start up Instructions 53 User Manual Enhanced miniMACS Glossary of Terms 53 Artisan Technology Group Quality Instrumentation Guaranteed
64. ersion that only executes for a period of 30 minutes ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 80 User Manual Enhanced miniMACS Introduction 80 User Manual Enhanced miniMACS Start up Instructions 80 User Manual Enhanced miniMACS Glossary of Terms 80 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Issue the following commands from inside OpenControl e Project Build Runtime e Project Activate Project Then close OpenControl and start The OpenControl Monitor ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 81 User Manual Enhanced miniMACS Introduction 81 User Manual Enhanced miniMACS Start up Instructions 81 User Manual Enhanced miniMACS Glossary of Terms 81 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The OpenControl Monitor Configuring the OpenControl Monitor The OpenControl Monitor needs to be set up with which default project it should execute when started To do this start the OpenControl Monitor OpenControl Monitor OF Xx File Edit View Options Tools Help Print Help Execution Mode real Y Flowcharts Logic Memory Output Forces Threads i Clear Output Hyperkernel 4 3 Trace Debug Kernel Copyright Imagination Systems Inc 1996 1997 1998 OpencControl Multiple Driver Execution Engine OCMDEE Version 2 0 Cr
65. ess OK to close the form and return to the Torque reading form The field Torque scalefactor in the latter form is now updated with the calculated value Press OK in this form to actually update the set up and download the new value to the servo Special Check Hold servo in position between steps if you want the servo to control this for you Using the Relay function radio buttons you define which event that should activate the relay output With Trace Sample Time you control the sample time with which traces are recorded Since a trace consists of up to 2000 samples a sample time of five ms makes it possible to record traces up to 10 seconds If the cycle is longer than the maximum trace time the older values are truncated ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 21 User Manual Enhanced miniMACS Introduction 21 User Manual Enhanced miniMACS Start up Instructions 21 User Manual Enhanced miniMACS Glossary of Terms 21 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Select current spindle Invokes the following dialogue Select current spindle x Here you select the current spindle Available spindles depends on the number of spindles that was set using the System dialogue This function is also available on the toolbar ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 22 User Manual Enhanced miniMACS Introductio
66. f the next 10 spindles i e spindle 10 to 19 e Module 3 Profibus slave node 6 handles inputs and outputs of the 12 spindles numbered 20 to 31 e Module 4 Profibus slave node 7 Includes the interface of the last spindle i e spindle 32 Inputs Module 1 Lamp Test If set high the following outputs will be set high Station OK Station NOK Group X OK Group X NOK Spindle X Running or NOK 2 nt Spinde eto 1 spindle wi be bypassed nex cycle 9 Innit spindle eto spindle wil be bypassed nextoyde Module 2 ON ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 64 User Manual Enhanced miniMACS Introduction 64 User Manual Enhanced miniMACS Start up Instructions 64 User Manual Enhanced miniMACS Glossary of Terms 64 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Inhibit Spindle 16 If set to 1 spindle will be bypassed next cycle Inhibit Spindle 17 If set to 1 spindle will be bypassed next cycle Inhibit Spindle 18 If set to 1 spindle will be bypassed next cycle el i i i Module 3 e e inot spinaie 21 sotto spindle wi be bypassed next cyee e inot spinaie 29 sotto spindle wil be bypassed next eye o inot Spnde2 sotto spindle wi be bypassed next eye Module 4 Inhibit Spindle 32 If set to 1 spindle will be bypassed next cycle pate oes O G o y O ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhan
67. hanced miniMACS Contents 86 User Manual Enhanced miniMACS Introduction 86 User Manual Enhanced miniMACS Start up Instructions 86 User Manual Enhanced miniMACS Glossary of Terms 86 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com SPC constants The table below gives the constants to use in the mathematical formulas Subgroup Divisor Facto Size s for rs for Estimat Con Standar Kimis d Dev d2 az D3 As B3 a ar fo ozs 198 z oj 2s alel EE sja az aJo 0o03 2 27 169 osse 102 2 o921 073 163 233 oso oss Ere 253 0952 oss 0 03 1 97 1 88 1 65 1 62 1 59 1 57 1 55 1 53 1 52 369 oos o19 oso 160 oso oso 1 50 149 azs oo o17 os2 158 ose os2 148 147 146 2 so oss ome oas 155 os2 ose 145 gt ss oso o15 oss 154 os1 osz 1 Oon E ooo a Lz os Lee ae e Le Ooo n a oss o2 o 174 093 032 108 Oooo ooon Oona ts e Oor Oos e 20 a ae as N 2 3 4 5 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 87 User Manual Enhanced miniMACS Introduction 87 User Manual Enhanced miniMACS Start up Instructions 87 User Manual Enhanced miniMACS Glossary of Terms 87 Artisan Technology
68. ightening cycle OK 4 Group 2 NOK Set high if any of the spindles included in group 2 finished the tightening cycle NOK 5 Group 3 OK Set high if all spindles included in group 3 finished the tightening cycle OK Group 3 NOK Set high if any of the spindles included in group 3 finished the tightening cycle NOK 7 Running or NOK Spindle 10 A high value indicates that the spindle either is running or that it finished with a NOK result Running or NOK Spindle 11 A high value indicates that the spindle either is running or that it finished with a NOK result Running or NOK Spindle 12 A high value indicates that the spindle either is running or that it finished with a NOK result 10 Running or NOK Spindle 13 A high value indicates that the spindle either is running or that it finished with a NOK result 11 Running or NOK Spindle 14 A high value indicates that the spindle either is running or that it finished with a NOK result 12 Running or NOK Spindle 15 A high value indicates that the spindle either is running or that it finished with a NOK result 13 Running or NOK Spindle 16 A high value indicates that the spindle either is running or that it finished with a NOK result 14 Running or NOK Spindle 17 A high value indicates that the spindle either is running or that it finished with a NOK result 15 Running or NOK Spindle 18 A high value indicates that the spindle either is running or that it finished with a NOK result 16 Running or NOK Spindle 19 A high
69. indletype and select the existing custom spindletype from the list The custom spindletype will be overwritten with the new values The saved spindletype will appear in the combo The custom spindletypes are saved in a special file in the same directory as the WinQCM exe file If this file is moved to another computer with WinQCM the custom spindletypes can be used there too ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 17 User Manual Enhanced miniMACS Introduction 17 User Manual Enhanced miniMACS Start up Instructions 17 User Manual Enhanced miniMACS Glossary of Terms 17 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Spindle Parameters Select a spindle type and press the Set default values button Default parameters will then be automatically inserted If the read values of the parameters doesn t correspond with the default values of the selected spindletype the label NOTE Not default values are displayed With the Maximum torque parameter the range for the spindle is selected Note The default value of Maximum torque is not stored in the servo meaning that if you read parameters from the servo WinQCM will present the default value of the selected spindletype which may differ from the manually edited value Depending on the spindle type the default values of the parameters are as follows SpindleQM Nom Cur scale Gear See
70. ing to the installation instructions ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 70 User Manual Enhanced miniMACS Introduction 70 User Manual Enhanced miniMACS Start up Instructions 70 User Manual Enhanced miniMACS Glossary of Terms 70 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The QCM2 Servo Unit Traces During each tightening cycle the servo drive unit stores measured torque and angle values in its internal memory with a resolution of 1ms sample A maximum of 2000 samples per trace can be stored Each such trace is stamped with Start of Cycle Time and combined with Stepstatus and EUN The servo drive unit will store the last 10 OK NOK traces plus the last 10 NOK traces in its internal memory Upon request by an operator the WinQCM E will ask a servo unit for retrieval of the selected trace over the Lan2 bus Digital I O A digital I O port is available on the servo drive unit aimed for testing and commissioning Two modes are available e Operation mode This is the standard mode when running the system Discrete I O is disabled and replaced by the Lan1 signalling as defined in Appendix 3 FBU Profibus interface e Commissioning mode Commissioning mode is selected by setting digital input X7A 8 to logic one Control over the Lan bus is disabled and the servo drive unit uses discrete I O signalling instead This mode is only to be u
71. is off Profibus cable Cable must be a shielded twisted par cable type AWG 24 The DIP switches on the connectors according to the amount off slaves Discret IO card If discreet IO is used then check the addresses Normally the first card should have address 04 and the second 05 PC Open the cover of the PC and check the setting of the DIP switches on the Kvaser CAN bord They should be set as the following 1 ON and 0 OFF 1 2 3 4 5 6 7 8 9 10 sw2 1 1 0 0 0 0 1 1 1 1 SW3 0 0 Lan1 Check that the two end of chain connectors with 120 Ohm resistors are mounted 15 pol HD Connector Pin 13 14 At FBU marked with Host At the last Servo marked with Next Lan2 Check that the 24 V power supply is supported to the last servo in chain Pin6 24V Pin9 GND 120 Ohm resistor between 2 7 UPS Check that the serial cable is connected to COM1 on the PC Servo connectors K7A B ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 72 User Manual Enhanced miniMACS Introduction 72 User Manual Enhanced miniMACS Start up Instructions 72 User Manual Enhanced miniMACS Glossary of Terms 72 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Ensure that K7A 6 is connected with K7B 34 on all servos Attention For servos which should have servo addresses above 15 you must install a jumper as follows For addresses between 16 and 30 C
72. isantg com one control mode defined by up to six parameters for example torque angle speed time etc See Tightening steps for a description of the different control modes The program capacity of a servo drive unit allows for storing of parameters for 64 steps The steps can be combined in up to 64 sets Programming is performed using the WinQCM E and the parameters are sent to the drive units through the Lan2 bus Since each drive unit can perform up to 16 different tightening sets the appropriate set number has to be selected before the start signal is sent The selected set number is the same for all drive units in the station but the content of the set i e the steps can vary between the drive units Each drive unit can be bypassed by an inhibit signal implying that it will not run a cycle at the start command The Start of Cycle Time and EUN codes must be included in the start command signal At the end of each tightening cycle the servo drive unit will store the final torque and angle values in its internal memory These values together with Start of Cycle Time and EUN Engine Unit Number are then retrieved by the WinQCM E through the Lan2 bus for SPC calculations and reporting Cabling For proper operation and functionality of the servo drive system all cables must be connected according to the user s manuals for QCM2 Ref 03 and FBU Ref 04 Ground and shield connections must also be performed accord
73. k in the Report box means that the Torque and Angle result will be reported from this step A report step is indicated with an R before the step number in the Tightening cycles Window table Note One step in a set must be marked for reporting If a tightening ends NOK for a spindle the reported data comes from the step that was NOK ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 15 User Manual Enhanced miniMACS Introduction 15 User Manual Enhanced miniMACS Start up Instructions 15 User Manual Enhanced miniMACS Glossary of Terms 15 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Copy tightening steps This function is used to copy tightening steps from one spindle to other spindles sau Cancel from step Bo to Bo Destination from spindle 2 to fio start with step fa You select where you want to copy from Source and where you want to copy to Destination In the example above step 3 4 and 5 are copied from spindle 1 to spindle 2 10 Note The report setting is only copied correctly if all 64 steps of a spindle are copied at the same time The default values in the dialog will copy all 64 steps ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 16 User Manual Enhanced miniMACS Introduction 16 User Manual Enhanced miniMACS Start up Instructions 16 User Manual Enhanced miniMACS Glossary of Terms 16 Artisan Techno
74. l The Field Bus Unit FBU is an intelligent communication controller manufactured by Atlas Copco Controls Ref 04 It can be equipped for communication through all common field buses on the market in this case the Profibus The information from the Profibus is processed and transferred to the CAN based communication bus called Lan1 used by the servo drive units This communication is further described in Appendix 3 FBU Profibus interface The servo drive units for the Enhanced miniMACS System are based on the new standard QCM2 drive units by Atlas Copco Controls Ref 03 These units have a new control card called CPU2 which includes all functions and I O s necessary for the required performance without any modifications Up to 32 drive units can be connected together in a station with one Station Controller and one FBU The QCM2 units come in three different power ranges 340V 15 25 and 50A with or without internal power supply i e Master QCM2 or Slave QCS2 All sizes will be supplied with the same application software The servo units communicates directly with the WinQCM E using the CAN bus Lan2 See Appendix 4 QCM2 CAN Communication for a description of the protocol used The functionality control of the servo drive part of the tightening system is stored in two sets of application software one for the QCM2 servo drive units and one for the FBU Basic Operation From the FBU and Servo units a typical tightening cycle
75. l spindles in the station have not ended the cycle correctly Dec actions apere Epenemeenemnaresemren tart 6 RM re tightening started he second RM action started Bit is cleared of a new station tart Communication eer communication with FBU or between FBU and spindles ailed 4 Parameter set failure Different set numbers returned from the active spindles 28 E stop DC Bus low from all active spindles Station Byte 2 1 Parameter bitO Confirm tightening set binary 1 2 Parameter bit1 Confirm tightening set binary 2 Dec EE Pal 4 lparameterbia onim tightening set binary 4 ig Parameter bit3 Confirm tightening set binary 8 So 2 fore 4 fore zafpare Spindle Byte Description Bytes 2 33 7 6 2 Time out Error 54 128 DC Bus low Dec EN Ex a 8 angeNok haenx o 64 128 ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 90 User Manual Enhanced miniMACS Introduction 90 User Manual Enhanced miniMACS Start up Instructions 90 User Manual Enhanced miniMACS Glossary of Terms 90 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Station Byte 3 optional Bit bec Description Comment 1 Stopped This use of this bit is optional Is set high if the Station Controller is stopped due to that the Automation PC issued a Stop order 1 2 Cycle Start Error This use of this bit is optional I
76. logy Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Spindle parameters Displays the Spindle parameter dialogue in which you configure the all of the spindle parameters for a spindle This includes spindle parameters torque parameters and special parameters Spindle parameters Spindle 1 x Spindle type OMR 42 25 Save custom spindletype Cancel Spindle Parameters Set default values IGAIN 10 DGAIN 2000 PGAIN 100 Nominal speed 6400 1pm Ramptime 200 mSec Gear f 2423 Current scale factor eso Maximum torque 135 Nm NOTE Not default values Torque Parameters Special parameters Set default values Dalibrates Hold servo in position between steps V Torque scalefactor fi 00 0 Trace sampletime E msec Filter constant fi x Relay function OK Input gain 4 x C Controller OK NOTE Not default values DvervaRage sutott It s possible to add custom spindletypes To do this first assign values to the Spindle Parameters and or Torque Parameters Then click the button Save custom spindletype This will bring up a dialog where a name are assigned to the custom spindletype To edit an existing custom spindletype first select the custom spindletype from the combo and click Set default values for Spindle Parameters and or Torque Parameters Then edit the vaules of the Parameters Then click Save custom sp
77. mentation Guaranteed 888 88 SOURCE www artisantg com Load parameters File View Spindle Setup Write all parameters to spindles Write all programmable parameters to the servos If the program is in off line mode it will automatically be set in on line mode after this operation Read all parameters from spindles Read all programmable parameters from the servos If the program is in off line mode it will automatically be set in on line mode after this operation Read all parameters from spindle 1 3 Error status No response from spindle 3 You can click Cancel during loading and the dialog will close The program will still be in on line mode The read parameters will not be updated in the program All written parameters though will remain in servo Access level File View Spindle Setup Load parameters SPC Trace Report MMS Help Logout User list The program has two different access levels The access level 3 is the highest with the right to modify everything In the user list you can add new users with an access level In the user list you also select a default access level This is the access level the program has when you start it If you select access level 3 as default access ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 26 User Manual Enhanced miniMACS Introduction 26 User Manual Enhanced miniMACS Start up Instructions 26 User Manual Enhanced miniMACS Gl
78. n 22 User Manual Enhanced miniMACS Start up Instructions 22 User Manual Enhanced miniMACS Glossary of Terms 22 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Setup System This function is used to set the main parameters of a system Here you can set how many spindles there are in the system the type of servos used and the torque unit Communication Displays the parameters of the CAN communication You are able to set the baud rate of the CAN board in the PC If you change the baud rate here you must ensure that the corresponding parameters are set in all servos as well ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 23 User Manual Enhanced miniMACS Introduction 23 User Manual Enhanced miniMACS Start up Instructions 23 User Manual Enhanced miniMACS Glossary of Terms 23 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com On line Off line Using this function you control the communication state of WinQCM E If the program is in Online mode it will be changed to Off line If the program is in Off line mode it will be changed to Online When going online you will be asked whether to Write all parameters to the spindles or Read all parameters from the spindles or just go ONLINE Without loading Before the dialog is shown the spindles are passed by to check if set up is
79. namely e The number of seconds elapsed since midnight Jan 1970 Handled as 32 bit integer using the following bytes Start Time byte 1MSB Start Time byte 0 Start Time byte 3 Start Time byte 2LSB e The number of milliseconds elapsed since midnight the current day Handled as 32 bit integer using the following bytes Start Time byte 5MSB Start Time byte 4 Start Time byte 7 Start Time byte 6LSB ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 93 User Manual Enhanced miniMACS Introduction 93 User Manual Enhanced miniMACS Start up Instructions 93 User Manual Enhanced miniMACS Glossary of Terms 93 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The control data included in Station byte no 5 above are listed below Machine Stop_N Logic zero will stop the tightening step in progress and put the servo in status NOK No other operations are involved Note Not to be used with emergency stop Byte ait pec ae 1 2 Controller ON Set the input to logic one to enable the servo drive to run a parameter set When Controller ON is set to logic zero the panel alarm indicators are cleared and the servo drive unit is reset from any error condition except breakdown in the resolver connection In this case you must power down the servo drive correct the error and power up again to reset the error signal Please note The output signal Controller O
80. nd row with the start time left blank You may also specify whether or not the cycle buffers should be cleared at the start of each shift and whether or not the report should be printed automatically at the end of the shift The field last cleared at shows the time when the buffers where last cleared Press the Print Current button if you want to force the printout of the report for the currently running shift The report will then be based on the data collected since the buffers where last cleared up till now It is also possible to print the previously generated shift report This is done pressing the Print Previous button The reports are printed to the printer set up as the default printer on the NT system ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 38 User Manual Enhanced miniMACS Introduction 38 User Manual Enhanced miniMACS Start up Instructions 38 User Manual Enhanced miniMACS Glossary of Terms 38 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com MMS File View Spindle Setup Loadparameters Accesslevel SPC Trace Report MMS Help All records New records Save All records Fills The MMS Window with the records of all cycles currently stored in the MMS queue New records Fills The MMS Window with the records of all cycles currently stored in the MMS queue that have not yet been read by the MMS server Note To update
81. nhanced miniMACS Introduction 6 User Manual Enhanced miniMACS Start up Instructions 6 User Manual Enhanced miniMACS Glossary of Terms 6 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The WinQCM E General The WinQCM E is mainly used for configuring the tightening program It displays result and status information from the tightening cycles calculates SPC Statistical Process Control values and retrives and displays traces recorded by the servos To do so it interacts both with the servos and the Station Controller WinQCM E also hosts the MMS interface ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 7 User Manual Enhanced miniMACS Introduction 7 User Manual Enhanced miniMACS Start up Instructions 7 User Manual Enhanced miniMACS Glossary of Terms 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Windows WinQCM E has three windows the Result window the Tightening cycles window and the MMS window The Results Window If the program is in on line mode and you switch to the result window results are continuously collected from all spindles in the system and viewed on the screen Satl_3sp qe1 WinQCM E File View Spindle Setup Loadparameters Accesslevel SPC Trace Repot MMS Help C JE spinaie 1 ON LINE V Log EUN 01234 4990015678 Torque high 8 0 1 180 2
82. nual Enhanced miniMACS Start up Instructions 33 User Manual Enhanced miniMACS Glossary of Terms 33 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com release the left mouse button Click on the right mouse button zoom out again Select in which form you want to present the trace with the Display control The following choices exists e Torque Vs Angle e Torque Vs Time e Angle Vs Time Press the Refresh button to re read and re display all traces currently selected Note that this may cause completely new traces to be displayed since which trace to up load from a spindle is pointed out relatively to the most recently recorded Press the Print button to print the trace currently viewed If you see a trace that is interesting in some respect and therefore want to store it on disk press the Save button You will then be presented a form where you may enter an optional comment that will be stored together with the trace Save trace Ea Select trace to save Sp 1 OK NOK Latest Cancel di Comment Enter a comment here ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 34 User Manual Enhanced miniMACS Introduction 34 User Manual Enhanced miniMACS Start up Instructions 34 User Manual Enhanced miniMACS Glossary of Terms 34 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Saved traces c
83. o delete and press Delete Subgroup To reset the values of the SPC buffers and all values calculated for all variables do press the button Clear Data To update the window press the button Refresh If you select Histogram you will get a different view The histogram is automatically scaled so there is 25 of the screen left of LTL and 25 right of UTL The limits are shown The full screen is divided into 20 classes ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 31 User Manual Enhanced miniMACS Introduction 31 User Manual Enhanced miniMACS Start up Instructions 31 User Manual Enhanced miniMACS Glossary of Terms 31 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com SPC Statistics x Station sati_2sp J Setno fE lt m C SPC and TDA Spindleno fi Variable Toque im 2 Short Term Trend Histogram Ut 2 Ltk 2 Ri R3 B5 R R3 Rit Clear Data Delete Giese Print Refresh No matter whether you display SPC and TDA Short Term Trend or Histogram you may study a particular part of the curve by zooming it in Place the mouse cursor on the left most position that is of interest press the left mouse button and drag the cursor to the right until the wanted area is marked and release the left mouse button Click on the right mouse button zoom out again If you want to have the current view on paper press the button Print Trace File View S
84. oadparameters Accesslevel SPC Trace Report MMS Help Ctrl N Ctrl 0 Open Save Ctrl S Save As Emme tl He Print Preview Pant Setup 1 satl_2sp_v4 gel 2 satl_2sp_v3 gel 3 satl_2sp_v2 ge1 4satl_2sp_v1 gel1 Exit Here you will find the standard functions for file handling New Open Save Save as Print and open any of last four files New Use this function to create and initiate a new set up When selected the System dialogue is displayed in which you must enter the main system parameters Open Opens an existing WinQCM E set up file This function is only available when the system is in OFF LINE mode Print If the currently displayed window is the Tightening cycles window then the current set up is printed The print out will list all parameters for each spindle included one spindle per page If the currently displayed window is the MMS window then current contents of the window will be printed It s possible to print all pages from page to page or current page Exit Ends the program If the current set up is modified you will be asked if you want to save the file ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 11 User Manual Enhanced miniMACS Introduction 11 User Manual Enhanced miniMACS Start up Instructions 11 User Manual Enhanced miniMACS Glossary of Terms 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg
85. on Guaranteed 888 88 SOURCE www artisantg com Appendix Appendix 1 SPC Calculations Calculations for subgroups Data in a subgroup is calculated as where n size of subgroup Calculations When the specified number of subgroups to use for calculations have been collected the SPC function will start calculations to determine the statistical stability This will be repeated every time a new subgroup is ready Calculations are performed in following steps m number of subgroups ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 84 User Manual Enhanced miniMACS Introduction 84 User Manual Enhanced miniMACS Start up Instructions 84 User Manual Enhanced miniMACS Glossary of Terms 84 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Calculation of Average of Average values Calculation of Average of Range or Standard deviation Calculation of Control levels ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 85 User Manual Enhanced miniMACS Introduction 85 User Manual Enhanced miniMACS Start up Instructions 85 User Manual Enhanced miniMACS Glossary of Terms 85 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Calculation of the process capabilities Cp and Cpk where for a normal distribution su sl 3 ASYQSW99085_202v6 doc 2000 06 20 User Manual En
86. on in order to read cycle data WinQCM keeps the 100 last cycles in memory and save this buffer on disk whenever the application is closed normally However if the application should terminate for other reasons the buffer data may be lost The number of cycles kept in memory can be changed in the ini file Section MMS key FIFOQUEUESIZE The interface available to the MMS server is implemented as a socket Only one client at the time is accepted The port number is default set to 5555 but can be defined in the ini file section MMS key PORTNO The interface only supports one task at the time meaning that a new request is not accepted until the previous is finished The interface supports the following telegrams e Request for all cycle data currently stored a FIFO buffer with 100 slots Request for all new cycle data since last request Cycle data response from WinQCM End of cycle data response from WinQCM Unknown telegram received response from WinQCM The telegrams are of variable length and their contents should be interpreted as ASCII characters i e as text All telegrams have the following basic format STX lt telegram type gt lt message body gt ETX Start of text decimal ASCll code 2 One byte One byte identifying the type of telegram lt message body gt The message A message of variable length zero or more bytes The contents depends on the lt telegram type gt End of text decimal ASClI code 3 On
87. onnect K7B 27 with K7A 16 For addresses above 31 Connect K7B 27 with K7A 15 ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 73 User Manual Enhanced miniMACS Introduction 73 User Manual Enhanced miniMACS Start up Instructions 73 User Manual Enhanced miniMACS Glossary of Terms 73 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Software Needed software and files Servo application Proda_03 HEE FBU application FBU_1 HEE Station Controller ver 1 4 or later Open SC_Setup EXE 1 disk Control application Install Promotion ECT Run Install EXE and follow the instructions Install WinQCM E Run Setup EXE and follow the instructions Install the Station Controller Run the self extracting program SC_Setup EXE Down load Servo software Copy the servo application software HEE to the directory ATLAS SERVO Repeat the following for each servo in the system Plug PC into Host Port on front of each servo one at a time Start with left most servo and work to right Make sure servo is powered up Start ECT software on the PC Select Window Terminal from menu you are now in terminal mode Setup servo software Type CRTL Z X where X represents the address for the servo Select Controller Force terminal mode from menu Select Controller Download from menu Select the servo application
88. or as decimal ASCII codes 02 50 03 WinQCM responds by sending one telegram for each cycle data currently stored that has not been sent earlier The data for the oldest cycle is sent first the second oldest is sent in the second telegram and so on until all stored and unread cycles are transferred To indicate that all cycle data are transferred WinQCM sends an end of cycle data telegram If there are no cycle data recorded which have not already been read this is the only telegram sent Cycle data This telegram is sent to the MMS server from WinQCM as a response to any of the cycle data requests Each telegram contains the information of one cycle data It consists of the following data Sequence number A sequence number Incremented for each cycle data read by WinQCM First cycle data read when WinQCM do not have any cycles in the buffer is given the value 1 1 the record has not been returned earlier Station name ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 43 User Manual Enhanced miniMACS Introduction 43 User Manual Enhanced miniMACS Start up Instructions 43 User Manual Enhanced miniMACS Glossary of Terms 43 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The number of spindles in the station EUN SS Date and time for when the cycle yyyy mm dd hh mm ss was started Set number executed po Overall cycle result OK NOK F
89. or descriptions of the interface to the FBU see Appendix 3 FBU Profibus interface There is also a version of the Station Controller that is controlled via a discrete digital I O interface This so called manual version of the Station Controller is used for stations where control input and output typically are handled using push buttons and lamps Except for the interface to the overriding control the functions of the manual version is the same as for the standard version See section 4 7 Interface of the manual Station Controller for a description of the interface of the manual version Common terms Cycle The complete execution of a set May be terminated before all steps of the set have been executed Results are reported to the WinQCM E on cycle basis Tightening cycle A tightening cycle includes the execution of the normal tightening set as well as any reject management set l e a tightening cycle may consist of several cycles ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 48 User Manual Enhanced miniMACS Introduction 48 User Manual Enhanced miniMACS Start up Instructions 48 User Manual Enhanced miniMACS Glossary of Terms 48 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Basic functionality The main function of the Station Controller is to start and stop the tightening cycles as ordered by the overriding Automation PC and to handle reject
90. or each spindle in the station the following is added Whenever this telegram is sent to the MMS server the corresponding cycle data stored in the WinQCM is marked as read This flag is used to figure out which cycle data that will be returned by the command Request for all cycle not currently read The telegram has the following format lt telegram type gt 3 decimal ASCIll code 51 lt message body gt See below ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 44 User Manual Enhanced miniMACS Introduction 44 User Manual Enhanced miniMACS Start up Instructions 44 User Manual Enhanced miniMACS Glossary of Terms 44 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Format of the cycle data message body The cycle data message is an ASCII string following the syntax described below extended BNF Texts printed in boldface are to be taken literally lt message body gt lt optSpindleList gt lt spindle gt lt SeqNo gt lt NewRecord gt new lt StationName gt lt EUN gt Automation PC lt Date gt lt Time gt lt SetNo gt lt CycleResult gt lt NoOfSpindles gt lt spindleNo gt lt finalTorque gt cycle lt MinTorqueLimit gt lt MaxTorqueLimit gt lt finalAngle gt cycle lt MinAngleLimit gt lt MaxAngleLimit gt lt inibited gt inhibited lt Status gt HE
91. or the specific set executed When the condition is met all spindles that still runs are stopped When running Group based RM the spindles are divided in groups Each group is monitored separately and each of them may specify different values for the maximum number of faulty spindles in the group When the specified condition is met for a group only the spindles belonging to the group is stopped all other spindles continue to execute Group based RM with priority differs from Group based RM only on one condition When the reject management condition is fulfilled for a given group say N then all spindles belonging to all groups with identity greater than N also will be stopped ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 50 User Manual Enhanced miniMACS Introduction 50 User Manual Enhanced miniMACS Start up Instructions 50 User Manual Enhanced miniMACS Glossary of Terms 50 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Which type of reject management to use is set up using the parameter RM_Type which takes one of the following values e 0 Standard RM e 1 Group based RM e 2 Group based RM with priority Independently of the reject management type selected the following five parameters must be defined for all normal tightening sets e Setxx_RM_MaxFailedSpindles Max number of failed spindles to allow only the failed spindles to be backed e Setxx_RM
92. ossary of Terms 26 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com level the user doesn t need to login since the user automatically has the right to do everything When no user is logged in access level 1 is selected Access level 1 has the right to look at everything but not to change anything This access level has the following rights and restrictions 1 Not allowed to open setups from file 2 Allowed to go online and read a set up from the servo 3 Not allowed to go offline This also prevents the user from exiting the application When WinQCM is offline the user is allowed to exit It s possible to change logged in user while WinQCM is running If a access level 1 user is online it s not possible to exit By logging in as a user with access level 3 it s possible to exit WinQCM ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 27 User Manual Enhanced miniMACS Introduction 27 User Manual Enhanced miniMACS Start up Instructions 27 User Manual Enhanced miniMACS Glossary of Terms 27 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com SPC File View Spindle Setup Load parameters Access level 5 Trace Repot MMS Help The built in SPC Statistical Process Control is very flexible and makes it possible to tailor data collection and calculations to suit most needs Data Collection for SP
93. pindle Setup Loadparameters Access level SPC Report MMS Help Each servo records the current torque and angle values during the tightening cycle This trace is stored in the servo Each servo stores the traces of the10 last cycles as well as the 10 last NOK cycles Here a cycle is found to be OK NOK based only on the result of each individual servo i e spindle OK NOK The menu alternative Trace View Traces invokes the Trace viewing window which is used to present the traces ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 32 User Manual Enhanced miniMACS Introduction 32 User Manual Enhanced miniMACS Start up Instructions 32 User Manual Enhanced miniMACS Glossary of Terms 32 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Spindle Trace hs Sp 1 OK NOK Latest Station Satt_asp x OK NOK latest sl Add gt gt p Spindle no fi x C NOK Latest 7 x Select saved trace Clear AII oococasas can tga sk awasaceedasnenanadacacnenadacnanasedsaceceeuclsasaannesabkanaananakaananeantocae eee ee eS Se ee ee ee eee en eee eee wn Pte te rn ge gn te et eer e yr ccc ere c sees eepessccscepescscscepecces secnanendeacwasasadoanaceacacd a anacanedaanenene Eiggasnocan dens anandacomdnanehcanenecnhnananna mine ma wn a a a a nt nt tn ee ete ge rl ee ee ee eee eee lll Mell lll al ad Rell atlas T s T aaa aaa dalle
94. rque field of the form The measuring continues until all Spindle Torque fields are filled with a value or that the button Stop Measuring is pressed For each value read from the spindle the corresponding torque values from the calibration equipment should be entered in the Monitored Torque field next to the Spindle Torque field This can be done during or after the measurements Pressing the Clear button for a result clears the entered values both the Spindle Torque and Monitored Torque This is done e g when one or more torque readings are found erroneous and can be done while measuring is on going ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 20 User Manual Enhanced miniMACS Introduction 20 User Manual Enhanced miniMACS Start up Instructions 20 User Manual Enhanced miniMACS Glossary of Terms 20 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com When all Spindle Torque and Monitored Torque fields have values the Calculate button is enabled Pressing causes a new value of the Torque Scalefactor to be calculated using the following formula Current value New value TS TM TS 1 where TS Average of the five 5 values entered in the Spindle Torque fields TM Average of the five 5 values entered in the Monitored Torque fields The new value calculated is automatically written in the corresponding field Pr
95. rs pressed and above the text three dots shows up and disappear When off line the button looks to be in its upper position A parameter change in On line mode is written directly to the spindle and it can be seen that the three dots change colour normally from blue to red during the transmission time New Open and Save are standard window symbols and will create open or save the set up Log will activate the saving of data to a file There is also a StatusLight that indicates the connection with the StationController This light has three different colours Grey WinQCM is offline Red WinQCM is online no connection with StationController Either OpenControl is not started or there is an error in the conneciton Green WinQCM is online connection with StationController is OK The status light can be disabled by setting a value in the ini file Section is STATIONCONTROLLER and the key is STATUSLIGHT value 0 1 Language The program is available in English German and French ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 41 User Manual Enhanced miniMACS Introduction 41 User Manual Enhanced miniMACS Start up Instructions 41 User Manual Enhanced miniMACS Glossary of Terms 41 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The MMS Interface General The miniMACS MMS server running on the miniMACS PC will access the WinQCM applicati
96. running or that it finished with a NOK result 10 Running or NOK Spindle 25 A high value indicates that the spindle either is running or that it finished with a NOK result 11 Running or NOK Spindle 26 A high value indicates that the spindle either is running or that it finished with a NOK result 12 Running or NOK Spindle 27 A high value indicates that the spindle either is running or that it finished with a NOK result 13 Running or NOK Spindle 28 A high value indicates that the spindle either is running or that it finished with a NOK result 14 Running or NOK Spindle 29 A high value indicates that the spindle either is running or that it finished with a NOK result 15 Running or NOK Spindle 30 A high value indicates that the spindle either is running or that it finished with a NOK result 16 Running or NOK Spindle 31 A high value indicates that the spindle either is running or that it finished with a NOK result Module 4 Running or NOK Spindle 32 A high value indicates that the spindle either is running or that it finished with a NOK result epee dCOCSCOCSOSSC C ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 68 User Manual Enhanced miniMACS Introduction 68 User Manual Enhanced miniMACS Start up Instructions 68 User Manual Enhanced miniMACS Glossary of Terms 68 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The Field Bus and Servo Units Genera
97. s optional Is set high if the parameter NoOfSpindles is set higher than 32 or if parameter RM_NoOfGroups is set higher than 16 All output signals above except for Running are cleared when a start is detected If set during the tightening cycle they remain set until either a reset or a new start command is issued In addition to the output signals on the station level the following signals indicates the status of the individual spindles Note that these signals are updated after each individual cycle Signal Description S Cycle NOK Cleared at cycle start Set high when a cycle finishes with an error and is cleared whenever a new cycle is started If the spindle finished NOK during the last tightening phase executing the normal or re tightening set this signal will be set just before the signal Running is cleared Remains set until next start Spindle Bypassed High indicates that the spindle is inhibited by the Automation PC This value is only changed at cycle start Torque NOK Cleared at cycle start Set high when a cycle is finished and the reported torque is out of limit If set it remains high until next start Angle NOK Cleared at cycle start Set high when a cycle is finished and the reported angle is out of limit If set it remains high until next start Controller OK Ready High if the servo spindle is OK and ready for start A low value indicates a servo spindle error If set it remains high until the system is
98. s set if all spindles did not eport that they are running within the time defined by the CycleStartTimer 1000 ms 2 4 FBUcomm Error This use of this bit is optional Is set high if the Station Controller have lost the contact with the FBU 3 WinQCM overrun This use of this bit is optional Is set high if the WinQCM did not finish reading cycle data within the time defined by the WinQCMTimer 3000 ms 16 Spindle Comm Error This use of this bit is optional Is set high if the FBU loose contact with one or more spindles L 5 aoe crashed This use of this bit is optional Is set high if NT crashes 64 Ready for Start This use of this bit is optional Is set high when the Station Controller accepts a new start order After that the signal Running goes low a new start is not accepted until the WinQCM has finished 7 128 JAPC comm Error This use of this bit is optional Is set high when the Station Controller has lost contact with the Automation PC Only active if supervision is enabled using one of the parameters StopSignallsNegated or SuperviseAPCLink elation Byte 4 optional a Jem O This use of this bit is optional It is set high if the parameter NoOfSpindles is set higher than 32 or if parameter IRM_NoOfGroups is set higher than 16 ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 91 User Manual Enhanced miniMACS Introduction 91 User Manual Enhanced miniMACS Start up Instructions 91
99. s set to one 1 the Station Controller uses this signal to supervise the connection to the Automation PC If found O zero the station will be stopped 7 128 Rest son pos edge station amp all spindles will be reset Spindle Bypass Byte 19 22 it poe Bescon Comment Gl een a e O a a a 5 32 linhibit Spindle 6 If set to 1 spindle will be bypassed next cycle g 64 inhibit Spindle 7 If set to 1 spindle will be bypassed next cycle 7 128 Inhibit Spindle 8 If set to 1 spindle will be bypassed next cycle Outputs The interface to the overriding Automation PC consists of the following output signals items printed in italic on grey background are optional and may be used if so wanted 4 16 Innibit Spindle 5 If set to 1 spindle will be bypassed next cycle Pinay See description below Spindle 32 byte Binary See description below Station byte 3 The use of this byte is optional Binary See description below Station byte 4 The use of this byte is optional Binary See description below ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 89 User Manual Enhanced miniMACS Introduction 89 User Manual Enhanced miniMACS Start up Instructions 89 User Manual Enhanced miniMACS Glossary of Terms 89 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Station Byte 1 All spindles in the station have ended the cycle correctly Al
100. sed for low level testing and debug purposes with reduced functionality Indicators There are ten LED indicators available on the front panel of the servo drive unit The upper two are controlled by hardware e Power On Green LED lit when 5V is available in the controller section e CPU OK Green LED lit when the CPU has started up and is running The remaining eight LED s 1xGreen 3xYellow 4xRed are controlled by the application software Overtemperature Red Overtemperature in the motor or in the servo drive unit e Resolver Fault Red O A resolver fault is detected iP ere ee A short circuit is detected in the motor or the motor cables ls Other Faults Red A fault is detected other then the three listed above ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 71 User Manual Enhanced miniMACS Introduction 71 User Manual Enhanced miniMACS Start up Instructions 71 User Manual Enhanced miniMACS Glossary of Terms 71 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Start up Instructions General This section describes typical tasks involved in commissioning of a miniMACS system Hardware check FBU Adjust the Profibus address of the FBU to 32 Switch location at back Mounting plate 2 switch at front 3 DIP Switch for the end resistor ON if last in chain and the connector do not have an end switch or end switch
101. ss or equal the Station Controller will start the execution of the next step for all spindles that still have status OK If it is greater then the on going cycle is terminated by machine stopping all spindles This will cause all still OK spindles to become NOK and report Machine Stop e If the cycle finishes with status NOK i e at least one spindle failed the reject management function is activated e Based on the number of NOK spindles either all spindles or only the NOK spindles will be backed using the back off set If the back off cycle ends successfully yet another set will be used to re tighten the joints ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 51 User Manual Enhanced miniMACS Introduction 51 User Manual Enhanced miniMACS Start up Instructions 51 User Manual Enhanced miniMACS Glossary of Terms 51 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Should the back off cycle fail then the station will not try to run the specified re tightening set but stop and report NOK for the overall cycle ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 52 User Manual Enhanced miniMACS Introduction 52 User Manual Enhanced miniMACS Start up Instructions 52 User Manual Enhanced miniMACS Glossary of Terms 52 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com e Should the station
102. station the FBU output buffer can be up to 160 bytes As soon as any value in this FBU buffer changes the complete 160 bytes are sent over the Profibus to update the corresponding Profibus input buffer in the Station Controller The 4 bytes of cycle status similar for each drive unit are as follows bec sianar name escrpon SSCS Step Sync OUT Step finished i e wait until all spindles ready with step for paralleling in multiple nut runner systems en 24 ing Eee a intorveerorsns 76 wartowe enoreie s a2 Mop ferrets SSCS ee fasa erorsne 7 2s Spine enor _ erorn SS SSOSCSC S S 2 a se cont nr Se Sn above a sercom Mors SetSeea mase 7 catraton enor reamme s a2 oreren rosee oooO r ras Dchustet focs CS 1 sep numero neson O ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 95 User Manual Enhanced miniMACS Introduction 95 User Manual Enhanced miniMACS Start up Instructions 95 User Manual Enhanced miniMACS Glossary of Terms 95 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com TT pene bine separ 2 sonm Sin the sepramber oi 2a sorme aon neseonome C e e seora oroen meseron i C o e atepnamers ortn nesep C fe e roe eoon C 7 e e eoon Appendix 4 QCM2 CAN Communication The Station Controller uses the CAN communication interface to program drive parameters and retrieve quantitative tightening data
103. tart up Instructions 13 User Manual Enhanced miniMACS Glossary of Terms 13 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Available Control Modes are given by the following table Control Description Mode Delay Continue with the next step after the Delay Time If the previous step was a Dyna Torque step keep the nutrunner current constant until the Delay Time is reached If the angle ended below Min Angle or at any time exceeded Max Angle then interrupt the cycle and set status NOK Torque Wait for Delay Start then run with the Speed value until pre set Target is reached If the angle ended below Min Angle or at any time exceeded Max Angle or if Max Time was reached before pre set Torque then interrupt the cycle and set status NOK Angle Wait for Delay Start then run with the Speed value until pre set Target is reached If the torque at any time exceeded Max Torque or if Max Time was reached before pre set Angle then interrupt the cycle and set status NOK Jo Wait for Delay Start then run with the Speed value as long as the Start input signal is logic one If the angle ended below Min Angle or at any time exceeded Max Angle or Max Torque or if Max Time was reached before the Start command was released then interrupt the cycle and set sta
104. the window with latest data you must actively select either of the two alternatives above The window is not automatically updated when new cycle data becomes available Save Stores the data currently displayed in the MMS window to disk ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 39 User Manual Enhanced miniMACS Introduction 39 User Manual Enhanced miniMACS Start up Instructions 39 User Manual Enhanced miniMACS Glossary of Terms 39 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Help menus File View Spindle Setup Loadparameters Access level SPC Trace Report MMS Help Topics Starts the help file for WinQCM E About WinQCM E Displays the WinQCM E about box where you can se the version number of the program ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 40 User Manual Enhanced miniMACS Introduction 40 User Manual Enhanced miniMACS Start up Instructions 40 User Manual Enhanced miniMACS Glossary of Terms 40 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Toolbar Following functions are in the toolbar New Open Save Print Select current servo On line Off line Log and a StatusLight Select current servo is a pop down menu with following selections Servo 1 servo 2 servo 32 On line Off line has the text on line In on line the button appea
105. this alternative to define how calculation should be performed and which variables to collect SPC Setup xi Standarddev Bo o Set 5 Torque Set 5 Angle Set 5 Torque Set 5 Angle Specify Subgroup size and if you want to use Range or Standard Deviation In the SPC and TDA frame set up values for normal SPC Do the same for the Short Term Trend frame These values will be used for calculations on all spindles and sets In the Variables to collect frame add those variables you want to check Select Spindle Set and Variable For Spindle you could specify All Press Add The variable shows up in the list box To take away a variable from the list select it and press the remove button X it you want to rearrange the order select an item and press the up or down buttons to move it upwards or downwards in the list ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 29 User Manual Enhanced miniMACS Introduction 29 User Manual Enhanced miniMACS Start up Instructions 29 User Manual Enhanced miniMACS Glossary of Terms 29 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com UTE ETE Constants su Bl p sl If you press the Information button ia dialogue box is presented where you can enter the UTL LTL su and sl values for the selected variable Results The menu alternative SPC Result invokes the View St
106. tisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 34 Station Control yteo See description below O 25 faon Coma pge _e dssipton eo Inhibit mask byte 0 Bypass spindle 1 to 8 bit 0 lt gt spindle 1 bit 1 lt gt spindle 2 etc Inhibit mask byte 1 Bypass spindle 9 to 16 bit 0 lt gt spindle 9 bit 1 lt gt spindle 10 etc Inhibit mask byte 2 Bypass spindle 17 to 24 bit 0 lt gt spindle 17 bit 1 lt gt spindle 18 etc 39 Inhibit mask byte 3 Bypass spindle 25 to 32 bit 0 lt gt spindle 25 bit 1 lt gt spindle 26 etc 40 Inhibit mask byte 4 Bypass spindle 33 to 40 bit O lt gt spindle 33 bit 1 lt gt spindle 34 etc The EUN code and Start Time data are sent to all servo drive units This is only information included for stamping report and trace data etc The Inhibit mask Station Control bytes and No of Spindles data are combined to an 8 bytes control word which is also sent to all drive units In each servo drive unit this information is first unpacked and then the Station Control bytes are combined with the bit in the Inhibit mask that corresponds to the drive units node number The modified Station Control bytes are then used as input to the local sequence handler in the servo drive unit The Start Time is not used internally by the FBU or the servos but it is reported to the WinQCM on request The Start Time is dived in two parts
107. tus NOK DynaTork Wait for Delay Start then run with the Speed value until pre set Target is reached Then continue to the next step which is always a Delay step see above If during the DynaTork step the angle ended below Min Angle or at any time exceeded Max Angle or if Max Time was reached before pre set Torque then interrupt the cycle and set status NOK Yield Wait for Delay Start then run with the Speed value until measured torque slope is less than a pre set Torque slope percentage Ratio of the torque slope reference Torque slope is measured continuously over a pre set Angle INC Torque slope reference is stored when Torque Ref TC is reached If the angle ended below Min Angle or at any time exceeded Max Angle or Max Torque or if Max Time was reached before pre set Torque Slope then interrupt the cycle and set status NOK Depending of the selected mode the editable parameters change according to below torque torque angle yes no ves ves no ves ves ves ves no yes no ves ves ves yes no ves ves no yes no ves ves no yes ves ves ves no yes no ves ves ves ves ves no ves ves _ No ves ves ves ves ves Y Y ves ves ves no The parameters TC INC and Ratio are only editable if the control mode is Yield Y Y Y
108. ual Enhanced miniMACS Contents 2 User Manual Enhanced miniMACS Introduction 2 User Manual Enhanced miniMACS Start up Instructions 2 User Manual Enhanced miniMACS Glossary of Terms 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Contents 1 Introduction 1 1 Overview 2 The WinQCM E 2 1 General 2 2 Windows 2 3 Menus 3 The MMS Interface 3 1 General 3 2 Request for all cycle data currently stored 3 3 Request for all cycles not currently read 3 4 Cycle data 3 5 Format of the cycle data message body 3 6 End of cycle data 3 7 Unknown telegram received 4 The Station Controller 4 1 General 4 2 Common terms 4 3 Basic functionality 4 4 Reject management 4 5 Interface to the Automation PC 4 6 The logic of the Station Controller 4 7 Interface of the manual Station Controller 5 The Field Bus and Servo Units 5 1 General 5 2 Basic Operation 5 3 Cabling 5 4 The QCM2 Servo Unit 6 Start up Instructions 6 1 General 6 2 Hardware check 6 3 Software 6 4 Configuration of the Station Controller 6 5 The OpenControl Monitor 7 Appendix 7 1 Appendix 1 SPC Calculations 7 2 Appendix 2 Interface to the Automation PC 7 3 Appendix 3 FBU Profibus interface ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 3 User Manual Enhanced miniMACS Introduction 3 User Manual Enhanced miniMACS Start up Instructions 3 User Manual Enhanced miniM
109. ulated automatically by the Calibrate function The Calibrate button is only enabled while online Default values for Torque scale dependent on transducer type are Torque transducer 20Nm 50Nm 100 Nm 200Nm 1000 Nm Default value 100 0 200 0 1000 Default value for the Filter constant is 1 Available filter settings are 0 1 2 and 3 where 0 gives the hardest filtering Default value for Input gain is 4 Available gain settings are 1 2 4 8 and 16 With gain 4 at least 100 of the transducer range can be used Increased gain results in that the usable transducer range is decreased and the resolution of the signal is increased ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 19 User Manual Enhanced miniMACS Introduction 19 User Manual Enhanced miniMACS Start up Instructions 19 User Manual Enhanced miniMACS Glossary of Terms 19 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com If you press the Calibration button the Torque Calibration form is displayed The Start Measuring button is enabled when there are at least one Spindle Torque field that is empty and a measuring is not started Press the Start Measuring button to start the measuring This will cause WinQCM to extract the torque value for the spindle in question from the cycle data packages received from the spindles The torque value is automatically written in the next free Spindle To
110. up to date If there are any mismatch you will be notified Select Write or Read if set up mismatch otherwise select Online and click OK If you choose Cancel the program will be in Off line mode See also Load parameters Read or Write registers for spindle 1 Log Settings Opens a dialogue in which you can configure how logging should be performed if enabled C Atlas LOG WinQCME log 10000000 ees ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 24 User Manual Enhanced miniMACS Introduction 24 User Manual Enhanced miniMACS Start up Instructions 24 User Manual Enhanced miniMACS Glossary of Terms 24 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Select which cycles you want to log using the Log Settings radio buttons e OK results only means that all not inhibited spindles must be OK for the cycle to be logged e NOK results only means that if one not inhibited spindle is NOK then the cycle is logged Specify the location of the log file file name and directory using field labelled Log file and the size of it using the Max size field ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 25 User Manual Enhanced miniMACS Introduction 25 User Manual Enhanced miniMACS Start up Instructions 25 User Manual Enhanced miniMACS Glossary of Terms 25 Artisan Technology Group Quality Instru
111. value indicates that the spindle either is running or that it finished with a NOK result ASYQSW99085_202v6 doc 2000 06 20 User Manual Enhanced miniMACS Contents 67 User Manual Enhanced miniMACS Introduction 67 User Manual Enhanced miniMACS Start up Instructions 67 User Manual Enhanced miniMACS Glossary of Terms 67 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Module 3 1 Group 4 OK Set high if all spindles included in group 4 finished the tightening cycle OK See 4 4 2 Group Based Reject Management for a description of groups 2 Group 4 NOK Set high if any of the spindles included in group 4 finished the tightening cycle NOK 3 Group 5 OK Set high if all spindles included in group 5 finished the tightening cycle OK 4 Group 5 NOK Set high if any of the spindles included in group 5 finished the tightening cycle NOK 5 Running or NOK Spindle 20 A high value indicates that the spindle either is running or that it finished with a NOK result Running or NOK Spindle 21 A high value indicates that the spindle either is running or that it finished with a NOK result 7 Running or NOK Spindle 22 A high value indicates that the spindle either is running or that it finished with a NOK result Running or NOK Spindle 23 A high value indicates that the spindle either is running or that it finished with a NOK result Running or NOK Spindle 24 A high value indicates that the spindle either is

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